Modular valve apparatus and system

ABSTRACT

A valved manifold module is disclosed, constructed and arranged to be readily connected in a chain with similar modules to form a manifold assembly. The modular manifolds allows for expansion or modification of the manifold assembly to control a group of pneumatically or hydraulically driven pumps, valves or combinations thereof in a liquid flow control apparatus. The valved manifold module can be configured to accept a group of four substantially identical valve assemblies, and can be controlled by a local controller mounted to the manifold module, thus forming an independently programmable valved manifold module. The resulting modular system is expandable to allow for coordinated operations of a liquid flow control system, using substantially independent controller functions originating at the manifold assembly level.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 16/839,548, filed Apr. 3, 2020, entitled ModularValve Apparatus and System and will be U.S. Pat. No. 11,549,502, issuingon Jan. 10, 2023 (Attorney Docket No. AA230), which is a divisionalapplication of U.S. patent application Ser. No. 14/967,093, filed Dec.11, 2015, entitled Modular Valve Apparatus and System, now U.S. Pat. No.10,613,553, issued on Apr. 7, 2020 (Attorney Docket No. P82), claimingthe benefit of U.S. Provisional Application Ser. No. 62/091,351 filedDec. 12, 2014 and entitled Modular Valve Apparatus and System (AttorneyDocket No. P33), which is hereby incorporated herein by reference in itsentirety.

U.S. patent application Ser. No. 14/967,093, filed Dec. 11, 2015,entitled Modular Valve Apparatus and System, now U.S. Pat. No.10,613,553, issued on Apr. 7, 2020 (Attorney Docket No. P82) is also aContinuation-in-Part of U.S. patent application Ser. No. 14/327,206filed Jul. 9, 2014 and entitled Valve Apparatus and System, Abandoned onJun. 23, 2021 (Attorney Docket No. M66), which claims the benefit ofU.S. Provisional Application Ser. No. 61/844,202 filed Jul. 9, 2013 andentitled Valve Apparatus and System (Attorney Docket No. K61), each ofwhich is hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This application relates generally to fluid flow control valves ormanifold valves, and more particularly to modular valved manifoldsystems.

BACKGROUND

Controlling the flow of a liquid may be accomplished by using a manifoldconnected to a pressurized fluid source—pneumatic or hydraulic—thatdistributes the pressurized fluid to a fluid-actuated liquid pumping orliquid flow control apparatus. Liquid flow valves or pumps (e.g., inmedical devices) may be fluidically actuated in a selectivemanner—either hydraulically or pneumatically—through the use ofcontroller-managed electromagnetic valves in a manifold assembly coupledto one or more fluid sources under positive or negative pressure. Themanifold valves selectively direct positive or negative fluidic pressureto the liquid flow control apparatus.

A manifold assembly is typically custom-designed and assembled for thespecific liquid flow control apparatus to which it is connected, andre-purposing the manifold for other applications (e.g. other pumpingdevices, or modified devices) is generally not feasible. ces.

Power consumption, heat generation and valve reliability can be asignificant problem in valved manifolds, particularly in systemsrequiring the manifold valves to frequently change states. The manifoldvalves may require a constant source of current to maintain a particularposition or state. In contrast, a bistable valve—stable in either of itspositions or states—may only require energy input to change its state.However, integrating bistable valve assemblies into a pressuredistribution manifold system may be overly complex and expensive.

Among some of the inventive improvements described herein: A modularmanifold assembly is described that can be readily modified by theaddition or subtraction of individual manifold modules in a concatenatedmanner, and may allow for rapid and convenient re-purposing of themanifold system. Manifold modules forming the building blocks for amanifold assembly are described that have standardized dimensions,inputs, outputs, and valve assemblies. Adding a standardized on-boardcontroller to each module may additionally permit the manifold system tolocally perform readily programmable and highly specialized functions invarious pump/valve devices. A controller connected to a valved manifoldis described that can be used to measure the amount of pressuredelivered to or present in the liquid flow control apparatus, cancontrol the rate of pressure delivery—either positive or negative, andcan allow for the venting of fluidic pressure in the liquid flow controlapparatus. Manifold modules are also described that can accommodatespecialized bistable valve sets so that each valved manifold module(with or without an on-board controller) can operate without undue powerconsumption or heat generation, and allow for individual valveassemblies to be easily replaceable.

SUMMARY OF THE INVENTION

A manifold module comprises: a manifold base reversibly connectable to apressure line containing pressurized fluid; a first valve assemblymounted to the manifold base; a controller mounted to the manifold baseand connected to the valve assembly; the manifold base being configuredto fluidically connect a pressure line inlet port of the manifold baseto an inlet of the valve assembly, to fluidically connect a cavity ofthe valve assembly to a pressure sensing port of the manifold base, tofluidically connect an outlet of the valve assembly to an outlet of themanifold base, and to fluidically connect the pressure line inlet portto a pressure line outlet port of the manifold base. The first valveassembly is configured to be electrically actuated by the controller toeither open or block communication between the inlet of the valveassembly and the cavity of the valve assembly, and the cavity of thevalve assembly is in fluid communication with the outlet of the valveassembly. The controller comprises a pressure sensor mounted on acontrol board, the pressure sensor configured to form a reversiblesealed connection with the pressure sensing port of the manifold base,the control board having one or more electrical output connectors forconnection to an electromagnetic coil to actuate the valve assembly, andthe control board having a first electronic communications connector forsending and receiving electronic communications to or from acommunications bus on a first side of the manifold module, and having asecond electronic communications connector for sending and receivingelectronic communications to or from the communications bus on a secondside of the manifold module. The manifold module is thereby configuredto reversibly connect with a second manifold module via the first orsecond electronic communications connector and via the pressure lineinlet port or the pressure line outlet port of the manifold base.

In another aspect, a modular manifold assembly comprises a plurality ofconcatenated manifold blocks, each manifold block having a flowpathconnecting a pressure line inlet port on a first side of the manifoldblock to a pressure line outlet port on a second side of the manifoldblock via a fluidic bus in the manifold block, the pressure line outletport of a first manifold block being connected to the pressure lineinlet port of an adjacent second manifold block. The first and secondmanifold blocks are each reversibly connected to each other, and areeach separately reversibly connected to a pressurized fluid line; eachmanifold block having a valve assembly receiving station for mounting apre-determined number of valve assemblies; each valve assemblycomprising an inlet configured to fluidically communicate with arespective fluidic bus port of the manifold block; each valve assemblyconfigured to be electrically actuated to open or block fluidcommunication between a cavity of the valve assembly and the inlet ofthe valve assembly, the cavity of each valve assembly in fluidcommunication with a respective outlet of the manifold block and influid communication with a respective pressure sensing port of themanifold block; and each valve assembly having electrical contacts foractuating the respective valve assemblies, the electrical contactsconfigured to connect to a programmable controller board mounted on themanifold block. The controller board comprises pressure sensorsconfigured to reversibly and sealably connect to respective sensingports on the manifold block. And each of the plurality of manifoldblocks is tasked by its programmable controller to control one of aplurality of pumps or valves of a liquid flow control apparatus.

In another aspect, a manifold module for controlling a pneumaticallyactuated diaphragm pump comprises: a manifold base reversiblyconnectable via a first pressure line inlet port to a first pressureline containing positively pressurized gas and a second pressure lineinlet port to a second pressure line containing negatively pressurizedgas; first, second, third and fourth valve assemblies, each mounted to avalve assembly receiving station on the manifold base; and a controllermounted to the manifold base and connected to the four valve assemblies.The manifold base is configured to fluidically connect the firstpressure line inlet port of the manifold base to a first inletrespectively of the first, second and third valve assemblies, tofluidically connect the second pressure line inlet port of the manifoldbase to a second inlet respectively of the first, second and fourthvalve assemblies, to fluidically connect a cavity of each of the thirdand fourth valve assemblies to a respective pressure sensing port of themanifold base, to fluidically connect an outlet of each of the valveassemblies to a respective outlet of the manifold base, and tofluidically connect the first and second pressure line inlet ports ofthe manifold base to respective first and second pressure line outletports of the manifold base. Each of the first and second valveassemblies is configured to be electrically actuated by the controllerto establish fluid communication between the cavity of the first orsecond valve assemblies and the first inlet of the first and secondvalve assemblies, or establish fluid communication between the cavity ofthe first or second valve assemblies and the second inlet of the firstand second valve assemblies. The third valve assembly is configured tobe electrically actuated by the controller to open or closecommunication between the cavity of the third valve assembly and thefirst inlet of the third valve assembly. The fourth valve assembly isconfigured to be electrically actuated by the controller to open orclose communication between the cavity of the fourth valve assembly andthe second inlet of said fourth valve assembly. The first valve assemblyis configured to fluidically connect to a first fluid inlet diaphragmvalve of the diaphragm pump, the second valve assembly is configured tofluidically connect to a second fluid outlet diaphragm valve of thediaphragm pump, and the third and fourth valve assemblies are configuredto fluidically connect to a control chamber of the diaphragm pump. Thecontroller comprises first and second pressure sensors mounted on acontrol board, the pressure sensors configured to form a reversiblesealed connection respectively with the pressure sensing ports of themanifold base connected to the cavities of the third and fourth valveassemblies. Thus the controller is configured to coordinate actuation ofthe four valve assemblies to open the inlet valve, close the outletvalve and generate a fill stroke in the diaphragm pump, or close theinlet valve, open the outlet valve and generate a deliver stroke in thediaphragm pump.

In another aspect, a manifold pressure measurement module comprises: amanifold base having a first pressure line inlet port for connection toa first pressure line containing positively pressurized gas, a secondpressure line inlet port for connection to a second pressure linecontaining negatively pressurized gas, a third inlet port for venting toatmospheric pressure; and a fourth inlet port for connection to acontrol chamber of a pneumatically actuated diaphragm pump. There arefirst, second third and fourth valve assemblies, each mounted to a valveassembly receiving station on the manifold base. A controller is mountedto the manifold base and connected to the four valve assemblies. Themanifold base is configured to fluidically connect the first pressureline inlet port to a first inlet of the first valve assembly, tofluidically connect the second pressure line inlet port to a first inletof the second valve assembly, to fluidically connect the third inletport to a first inlet of the third valve assembly, and to fluidicallyconnect the fourth inlet port to a first inlet of the fourth valveassembly. The manifold base is also configured to connect valve cavitiesof each valve assembly to respective pressure sensing ports of themanifold base, and to connect each of the valve cavities to a referencereservoir of known volume. The first, second, third and fourth valveassemblies are configured to be selectively electrically actuated by thecontroller to open or close communication between the cavities of thevalve assemblies and the first inlets of the valve assemblies. Thecontroller comprises first, second, third and fourth pressure sensorsmounted on a control board, the pressure sensors configured to form areversible sealed connection respectively with the pressure sensingports of the manifold base. The controller is thereby configured tooperate the first, second, third and fourth valve assemblies to chargethe reference reservoir with positive or negative pneumatic pressure, orto open the reference reservoir to atmospheric pressure, and tofluidically connect the reference reservoir with the control chamber ofthe diaphragm pump to equalize pressures between the control chamber andthe reference reservoir, and to record pressures in one or more valvechambers before and after pressure equalization. This procedure allowsthe controller to calculate a volume of the pump control chamber (andthus a volume of the liquid in the pumping chamber) using one or moremodels based on the ideal gas laws.

In another aspect, a valve assembly comprises a shuttle within a valvecavity configured to move linearly from a first position blocking afirst inlet of the valve cavity to a second position allowing the firstinlet to fluidly communicate with the valve cavity, the movement of theshuttle being actuated electromagnetically, magnetically, or through abiasing force applied by a spring. A molded insert having an outer wallis configured to conform to an inner wall of the valve cavity, and hasan inner wall configured to surround the shuttle and permit the shuttleto move from the first position to the second position. The moldedinsert has an inlet orifice configured to mate with the first inlet ofthe valve cavity and to be interposed between the first inlet of thevalve cavity and a first face of the shuttle. The molded insert has anoutlet orifice configured to fluidly communicate with a fluid outlet ofthe valve cavity. The first molded insert is manufactured from anelastomeric or plastic material that reduces acoustical noise generatedby movement of the shuttle.

In another aspect, a fluid pumping system comprises a cassette having aflexible diaphragm; a system controller; and a manifold module. Themanifold module comprises: a manifold base reversibly connectable to apressure line containing pressurized fluid; a first valve assemblymounted to the manifold base; and a module controller mounted to themanifold base and connected to the valve assembly. The manifold base isconfigured to fluidically connect a pressure line inlet port of themanifold base to an inlet of the valve assembly, to fluidically connecta cavity of the valve assembly to a pressure sensing port of themanifold base, to fluidically connect an outlet of the valve assembly toan outlet of the manifold base, and to fluidically connect the pressureline inlet port to a pressure line outlet port of the manifold base. Thefirst valve assembly is configured to be electrically actuated by themodule controller to either open or block communication between theinlet of the valve assembly and the cavity of the valve assembly, andthe cavity of the valve assembly being in fluid communication with theoutlet of the valve assembly. The module controller comprises a pressuresensor mounted on a control board, the pressure sensor configured toform a reversible sealed connection with the pressure sensing port ofthe manifold base, the control board having one or more electricaloutput connectors for connection to an electromagnetic coil to actuatethe valve assembly, and the control board has a first electroniccommunications connector for sending and receiving electroniccommunications to or from a communications bus on a first side of themanifold module. The control board also has a second electroniccommunications connector for sending and receiving electroniccommunications to or from the communications bus on a second side of themanifold module. The control board is configured to receive a summarycommand from the system controller, the control board is configured togenerate, based on the summary command, at least one module commandaddressed to the first valve assembly, the at least one module commandenabling selective application of pressure to the flexible diaphragm.The manifold module is thereby configured to reversibly connect with asecond manifold module via the first or second electronic communicationsconnector and via the pressure line inlet port or the pressure lineoutlet port of the manifold base.

In another aspect, a fluid flow control system for controlling a pumpcassette comprises: a pump cassette including a diaphragm pump having aninlet valve and an outlet valve; a system controller; a manifold basereversibly connectable via a first pressure line inlet port to a firstpressure line containing positively pressurized gas and a secondpressure line inlet port to a second pressure line containing negativelypressurized gas; first, second, third and fourth valve assemblies, eachmounted to a valve assembly receiving station on the manifold base; andan on-board controller mounted to the manifold base and connected to thefour valve assemblies. The manifold base is configured to fluidicallyconnect the first pressure line inlet port of the manifold base to afirst inlet respectively of the first, second and third valveassemblies, to fluidically connect the second pressure line inlet portof the manifold base to a second inlet respectively of the first, secondand fourth valve assemblies, to fluidically connect a cavity of each ofthe third and fourth valve assemblies to a respective pressure sensingport of the manifold base, to fluidically connect an outlet of each ofthe valve assemblies to a respective outlet of the manifold base, and tofluidically connect the first and second pressure line inlet ports ofthe manifold base to respective first and second pressure line outletports of the manifold base. Each of the first and second valveassemblies is configured to be electrically actuated by the on-boardcontroller to establish communication between the cavity of said firstor second valve assemblies and the first inlet of the first and secondvalve assemblies, or establish communication between the cavity of thefirst or second valve assemblies and the second inlet of the first andsecond valve assemblies. The third valve assembly is configured to beelectrically actuated by the on-board controller to open or closecommunication between the cavity of the third valve assembly and thefirst inlet of the third valve assembly. The fourth valve assembly isconfigured to be electrically actuated by the on-board controller toopen or close communication between the cavity of the fourth valveassembly and the second inlet of the fourth valve assembly. The firstvalve assembly is configured to fluidically connect to the inlet valveof the diaphragm pump, the second valve assembly is configured tofluidically connect to the outlet valve of the diaphragm pump, and thethird and fourth valve assemblies are configured to fluidically connectto a control chamber of the diaphragm pump. The on-board controllercomprises first and second pressure sensors mounted on a control board,the pressure sensors configured to form a reversible sealed connectionrespectively with the pressure sensing ports of the manifold baseconnected to the cavities of the third and fourth valve assemblies. Andthe on-board controller is configured to coordinate actuation of thefour valve assemblies to open the inlet valve, close the outlet valveand generate a fill stroke in the diaphragm pump, or close the inletvalve, open the outlet valve and generate a deliver stroke in thediaphragm pump, with the system controller being configured to providecommands to the on-board controller that may include a start pumpingcommand, a stop pumping command, or a command to pump a pre-determinedquantity of liquid.

The details of one or more embodiments are set forth in the accompanyingdrawings and the description below. Other features and advantages willbecome apparent from the description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of the one embodiment of a bistable valve;

FIG. 1B is a cross-sectional view of one embodiment of a bistable valvewith a shuttle capable of being actuated by electromagnets;

FIG. 1C is another cross-sectional view of the embodiment of FIG. 1A;

FIG. 1D is a partial cross-sectional view of the embodiment of FIG. 1Awith a more detailed view of the shuttle;

FIG. 1E is a top view of a ring plate according to one embodiment;

FIG. 2A is a perspective view of one embodiment of a shuttle;

FIG. 2B is a cross-sectional view of the shuttle of FIG. 2A, showing twodisk magnets oriented back-to-back;

FIG. 2C is a view of the magnetization vector and magnetic flux path ofone embodiment of a shuttle;

FIG. 2D is a view of the magnetic flux path of one embodiment when theshuttle is acted upon by an electromagnetic coil;

FIG. 2E is a view of the magnetic flux path of one embodiment, when theshuttle is acted upon by an electromagnetic coil in the presence of aring plate;

FIG. 2F is a perspective view of one embodiment of a shuttle havingmechanical retainers;

FIG. 2G is a cross-sectional view of the shuttle of FIG. 2F, showingmechanical retainers;

FIG. 3A is a perspective view of one embodiment of a shuttle showing twostacked ring magnets;

FIG. 3B is a cross-sectional view of the shuttle of FIG. 3A;

FIG. 4A is a perspective view of one embodiment of a shuttle showingradially-oriented magnets;

FIG. 4B is a cross-sectional view of the shuttle of FIG. 4A;

FIG. 4C is a top cross-sectional view of the shuttle of FIG. 4A;

FIG. 4D is a cross-sectional view of one embodiment of a shuttle showingradially-oriented magnets;

FIG. 5A is a perspective view of one embodiment of a shuttle showingradially-oriented magnets in a stacked pattern;

FIG. 5B is a cross-sectional view of the shuttle of FIG. 5A;

FIG. 5C is another cross-sectional view of the shuttle of FIG. 5A;

FIG. 6A is a front view of one embodiment of a shuttle having guideposts on either side of the shuttle;

FIG. 6B is a cross-sectional view of one embodiment of a shuttle havingelastomer guide posts;

FIG. 6C is a cross-sectional view of one embodiment of a shuttle havingconical elastomer guide posts;

FIG. 7 is a cross-sectional view of one embodiment of a valve apparatusand system with the shuttle encased in a membrane;

FIG. 8 is a cross-sectional view of one embodiment of a valve apparatusand system including stacked electromagnetic coil geometry;

FIG. 9A is a cross-sectional view of one embodiment of a valve apparatusand system, utilizing a cantilever armature instead of a shuttle;

FIG. 9B is a cross-sectional view of one embodiment of a valve apparatusand system, using an axially-oriented magnet in conjunction with acantilever armature;

FIG. 9C is a cross-sectional view of another embodiment of a valveapparatus and system, using a radially-oriented magnet in conjunctionwith a cantilever armature;

FIG. 10A is a perspective view of one embodiment of a valve apparatusand system arranged in an array;

FIG. 10B is a top view of a circuit board having multiple flatelectromagnetic coils according to one embodiment;

FIG. 10C is a cross-sectional view of one embodiment of a valveapparatus and system arranged in an array;

FIG. 11A is a cross-sectional view of one embodiment of a valveapparatus and system integrated into a pumping system;

FIG. 11B is a cross-sectional view of another embodiment of a valveapparatus and system integrated into a pumping system;

FIG. 12A is a cross-sectional view of one embodiment of a valveapparatus and system arranged in an array;

FIG. 12B is another cross-sectional view of one embodiment of a valveapparatus and system arranged in an array;

FIG. 13 is a top view of an outer plate for use in an array geometryembodiment;

FIGS. 14A-14C are a perspective view and two cross-sectional views of anembodiment of a valve apparatus;

FIGS. 15A-15B are a perspective view and a cross-sectional view of anembodiment of a valve apparatus;

FIGS. 16A-16B are a perspective view and a cross-sectional view of anembodiment of a valve apparatus;

FIGS. 17A-17B are a perspective view and a cross-sectional view of anembodiment of a valve apparatus;

FIGS. 17C-17D are a perspective view and a cross-sectional view of ashuttle for the valve apparatus of FIGS. 17A-17B;

FIG. 17E is a cross-sectional view of the valve apparatus of FIGS. 17Aand 17B;

FIGS. 18A-18B are a perspective view and a cross-sectional view of anembodiment of a valve manifold;

FIGS. 19A-19B are a perspective view and a cross-sectional view of anembodiment of a valve assembly configured as a pressure regulator;

FIGS. 20A-20C are a cross-sectional view and perspective views of anembodiment of a valve apparatus; and

FIGS. 21A-21C are a cross-sectional view and perspective views of anembodiment of a valve apparatus.

FIG. 22 depicts a representational view of an interior cavity of anexample bistable valve apparatus;

FIG. 23 is a perspective view of an example coil assembly for a bistablevalve assembly;

FIG. 24 is a perspective view of an valve assembly showing connectorsattached to coil assembly terminals;

FIG. 25A-C are a cross-sectional view and perspective views of anembodiment of a valve apparatus;

FIG. 26A is a plan view of a valve assembly;

FIG. 26B is a cross-section view of the valve assembly of FIG. 26A

FIG. 26C is an exploded view of the valve assembly of FIGS. 26A and 26B;

FIG. 27A is a plan view of a valve assembly;

FIG. 27B is a cross-sectional view of the valve assembly of FIG. 27A;

FIG. 27C is an exploded view of the valve assembly of FIGS. 27A and 27B;

FIG. 27D is a cross-sectional view of a portion of an insert for a valveassembly;

FIG. 28A is a plan view of a valve assembly;

FIG. 28B is a cross-sectional view of the valve assembly of FIG. 28A;

FIG. 28C is an exploded view of the valve assembly of FIGS. 28A and 28B;

FIG. 28D is a perspective view of a monolithic valve gasket which may beincluded in a bi-stable valve assembly;

FIGS. 29A-D are cross-sectional and perspective views of an embodimentof a valve apparatus;

FIG. 30A is a plan view of a valve assembly;

FIGS. 30B-C are perspective views of the valve assembly of FIG. 30A;

FIGS. 30D-E are cross-sectional views of the valve assembly of FIGS.30A-C;

FIG. 31 is a cross-sectional view of an interior cavity of a bi-stablevalve in which the shuttle includes a keyed alignment feature;

FIGS. 32A-32C are perspective, cross-sectional and exploded views of anexample shuttle which includes a number of keyed alignment features;

FIGS. 33A-33B are perspective views of an example shuttle;

FIG. 33C is a cross-sectional view of an exemplary valve cavity in whichthe shuttle of FIGS. 33A-B is positioned;

FIG. 34A depicts an abstracted block diagram of a valve module;

FIG. 34B depicts an abstracted block diagram of a manifold comprising anumber of valve modules;

FIGS. 34C-34G depict a number of representational block diagrams ofpneumatic pump/valve systems controlled by modular manifold assemblies;

FIG. 34H depicts a representational block diagram of a modular manifoldassembly controlling a variety of electrical or electronic components ordevices;

FIG. 35A is a perspective view of a programmable valved manifold module;

FIG. 35B is a perspective view of two connected or concatenatedprogrammable valved manifold modules;

FIG. 35C shows a programmable valved manifold module of FIG. 35A withthe controller board disconnected from the valve assemblies and themodule base;

FIG. 35D is a perspective view of the programmable valved manifoldmodule of FIG. 35A showing pneumatic output lines of the module;

FIG. 35E is a perspective view of manifold assembly comprising a stackof four banks of grouped or concatenated programmable valved manifoldmodules;

FIG. 35F depicts a block diagram of the connections of a manifoldassembly comprising a stack of four banks of grouped or concatenatedprogrammable valved manifold modules;

FIG. 36 depicts a pneumatic schematic diagram of a valve manifold modulecontrolling a pump/valve unit;

FIG. 37 depicts a block diagram of the pneumatic connections of apressure measurement valved manifold module;

FIG. 38A depicts a block diagram of a pumping valved manifold modulethat is paired with a fluid pressure measurement valved manifold module;

FIG. 38B shows a block diagram of a pressure measurement valved manifoldmodule connected to a reference reservoir and a pump control chamber;

FIG. 39 depicts a block diagram of a regulator valve manifold modulewith pressure reservoirs or accumulators;

FIG. 40 is a perspective view of an example of a pneumatic isolationassembly mountable to a valve slot of a valved manifold module;

FIGS. 41A-B depict a schematic representation of a group of valvedmanifold modules configured to control pumping of fluid through a fluidhandling cassette;

FIGS. 42A-B depict another schematic representation of a group of valvedmanifold modules configured to control pumping of fluid through a fluidhandling cassette;

FIGS. 43A and 43B depict a schematic representation of an implementationof a manifold assembly comprising a group of programmable valvedmanifold modules operating various pumps and valves of a hemodialysissystem;

FIG. 44 depicts a flowchart outlining a procedure for initiatingautomatic enumeration of manifold modules in a manifold assembly;

FIG. 45 depicts a flowchart outlining a procedure for automaticallyenumerating manifold modules on a communications bus;

FIG. 46 depicts a flowchart outlining a procedure for enumerating a newmodule being installed onto a communications bus that has already beenenumerated;

FIG. 47 depicts a flowchart outlining a procedure which may be used toassign tasks to various modules in a manifold assembly;

FIG. 48 depicts a flowchart outlining a procedure for commandingoperation of a module;

FIG. 49 depicts a flowchart outlining a procedure of transmittingfeedback data from a valve module to a main controller;

FIG. 50 depicts a flowchart outlining another example method forproviding feedback from a module;

FIG. 51 depicts a flowchart outlining a procedure for commandingoperation of a valve within a valve module;

FIGS. 52A-B depict a flowchart outlining a procedure for a valvemanifold module actuating the pumping of fluid through a pump chamber ofa cassette;

FIG. 53 depicts a flowchart outlining a procedure for commanding a pumpstroke from a pump chamber of a cassette via a number of valve modules;

FIG. 54 depicts a flowchart outlining a procedure for commandingcoordinated pumping of fluid through multiple pump chambers;

FIG. 55 depicts a flowchart outlining a pumping command set having beensent from a main controller and a procedure for commanding pumping offluid with one pumping chamber in a filled state;

FIG. 56 shows an exemplary graph depicting pressure of a control chamberof a pump over time during a pump stroke;

FIG. 57 depicts a flowchart outlining a procedure for detecting anend-of-stroke condition with a chamber control module controller;

FIG. 58 depicts a flowchart outlining a procedure for detecting anend-of-stroke condition with a chamber control module controller;

FIG. 59 depicts a flowchart outlining a procedure for limiting thetoggle frequency of a valve within a valve module; and

FIG. 60 depicts a flowchart outlining a procedure that may be used tocontrol the amount of pressure delivered to a pump control chamber.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Bistable Valve Embodiments

One aspect of a valve apparatus and system is illustrated in FIGS.1A-1E. This aspect of the bistable valve 13 includes a first pressureinlet 12, a second pressure inlet 14, a shuttle 16, circuit boards 18,each having an electromagnetic coil 34 to actuate the shuttle 16, avalve manifold 20 having an interior valve cavity 32, and a commonoutput orifice 22 in fluid communication with the valve cavity 32.

The first pressure inlet 12 may have a hollow post portion 28 extendinginto the valve cavity 32. In some embodiments, this may be constructedof a ferrous material. Similarly, the second pressure inlet 14 has ahollow post portion 30 extending into the valve cavity 32 substantiallyopposite from the first pressure post 28, and may also be constructed ofa ferrous material. In some aspects, the first pressure post 28 mayinclude a first pressure orifice 24, which is in fluid communicationwith the first pressure inlet 12. Similarly, the second pressure post 30may have a second pressure orifice 26 which may be in fluidcommunication with the second pressure inlet 14.

A first circuit board 18 having a first electromagnetic coil 34 isdisposed around the first pressure post 28 such that, when energized,the first electromagnetic coil 34 supplies a magnetic charge to thefirst pressure post 28. Similarly, a second circuit board 18 having asecond electromagnetic coil 34 is disposed around the second pressurepost 30 such that, when energized, the second electromagnetic coil 34supplies a magnetic charge to the second pressure post 30. An outerplate 19 constructed of a ferrous material may be disposed around eachof the first pressure post 28 and the second pressure post 30, andabutting an insulating layer on the outer edge 21 of each of the circuitboards 18. In some aspects, each of the outer plates 19 may be connectedto each other by way of fasteners 17 also constructed of a ferrousmaterial. A ring plate 23 may be included, constructed of a ferrousmaterial and having a central opening 25 defined by an inner edge 27,disposed in the valve manifold 20 such that the ring plate 23 is incontact with each fastener 17. The central opening 25 surrounds theshuttle 16 within the interior valve cavity 32. The outer plates 19 andfasteners 17 form a box of ferrous material surrounding theelectromagnetic coils 34, the first pressure post 28, the secondpressure post 30, the ring plate 23, and the shuttle 16. The outerplates 19, fasteners 17, ring plate 23, first pressure post 28 andsecond pressure post 30 may all be constructed of a ferrous materialincluding, but not limited to, iron, stainless steel or a nickel-ironalloy such as mu metal or, more specifically, a 42 nickel-iron alloy,the composition of which contains approximately 42% nickel.

The shuttle 16 may be sealed against the first pressure orifice 24 in afirst stable position such that the second pressure orifice 26 is influid communication with the interior valve cavity 32. One or moremagnets (e.g., see magnets 38, FIG. 2B) may be mounted or attached tothe shuttle 16 to provide an attractive force between the shuttle 16 andcomponents surrounding the pressure orifice 24 or 26. Alternatively, theshuttle 16 may be sealed against the second pressure orifice 26 in asecond stable position such that the first pressure orifice 24 is influid communication with the interior valve cavity 32. In each staticsealing position, the shuttle 16 is held in place by a magneticattraction from the shuttle 16 to either the first pressure post 28 orthe second pressure post 30, whichever is being sealed.

To switch the position of the shuttle 16 from sealing against the firstpressure orifice 24 to sealing against the second pressure orifice 26,the electromagnetic coils 34 disposed around each of the second pressurepost 30 and the first pressure post 28 are energized such that the firstpressure post 28 exerts a repellant force on the shuttle 16, while thesecond pressure post 30 exerts an attractive force on the shuttle 16.One or both forces may be sufficient to actuate movement of the shuttle16. In one embodiment, both the attractive and repellant forces workingtogether are enough to overcome the static magnetic force currentlyholding the shuttle 16 to the first pressure orifice 24. Once thisoccurs, the shuttle 16 moves linearly through the valve cavity 32 fromsealing the first pressure orifice 24 to sealing the second pressureorifice 26. Once this switch occurs, the electromagnetic coils 34 ceaseto be energized and the shuttle 16 is retained against the secondpressure orifice 26 through a static magnetic attraction.

Similarly, to switch the position of the shuttle 16 from sealing againstthe second pressure orifice 26 to sealing against the first pressureorifice 24, the electromagnetic coils 34 disposed around each of thefirst pressure post 28 and the second pressure post 30 are energizedsuch that the second pressure post 30 exerts a repellant force on theshuttle 16, while the first pressure post 28 exerts an attractive forceon the shuttle 16. Either or both forces may be sufficient to actuatemovement of the shuttle. In an embodiment, both the attractive andrepellant forces working together are enough to overcome the magneticforce statically holding the shuttle 16 to the second pressure orifice26. Once this occurs, the shuttle 16 moves linearly through the valvecavity 32 from sealing the second pressure orifice 26 to sealing thefirst pressure orifice 24. Once this switch occurs, the electromagneticcoils 34 cease to be energized and the shuttle 16 is retained againstthe first pressure post 28 through a static magnetic attraction.

In an exemplary implementation, the electromagnetic coils 34 are bothenergized in series in one polarity to actuate the shuttle 16 in onedirection. Similarly, to actuate the shuttle 16 in the oppositedirection, both electromagnetic coils 34 are energized together inseries in the opposite polarity.

Optionally, the coils 34 may be energized by discharging current from acharged capacitor. Once the capacitor is discharged, current ceases tocharge the respective coil 34, and the shuttle 16 is held against eitherthe first pressure post 28 or the second pressure post 30, by way ofstatic magnetic attraction while the capacitor recharges. Use of acapacitor to charge the electromagnetic coils 34 may have certainsafety-related advantages. It may help to limit the amount of continuouscurrent flowing through the coils 34 to reduce the possibility ofover-heating. It may also reduce the size, complexity and cost of theapparatus. In one example, a single capacitor may be used to energizemultiple valves. In alternate embodiments, the electromagnetic coils 34may be energized individually by separate sources of electrical currentor separate charging devices.

In a yet simpler implementation, actuation of the shuttle 16 may onlyrequire activation of a single electromagnetic coil to move the shuttle16 in either direction or sealing position.

To reduce the acoustic noise generated during displacement of a shuttle16, the interior valve cavity 32 may be sized to minimize the traveldistance of the shuttle 16 when actuated from one sealing position toanother sealing position. Reduction of shuttle travel may help toincrease the life of a valve, as less shuttle kinetic energy is used inoperating the valve. A shorter shuttle 16 excursion may also reduce thepossibility of misalignment with the valve seats during displacement. Inan example, the shuttle 16 may be sized such that it need only displace˜5% or less of the length of the interior valve cavity to transitionfrom one sealing position to another sealing position. Morespecifically, for example, the interior valve cavity 32 may measureabout 0.200″ long and the shuttle 16 may measure about 0.190″ long.

Optionally, a shuttle for a bistable valve may include at least oneelastomeric layer. An elastomeric layer may be present on the outwardfaces of the shuttle that seal the inlets to an interior valve cavity ofa bistable valve. The thickness as well as the material comprising theelastomer layer(s) can vary. In some examples, the thickness of theelastomer layer may be between about 0.0010″ and 0.0030 thick. Morespecifically, for example, the thickness of the elastomer layer may beabout 0.0020″ thick.

Referring now also to FIGS. 2A and 2B, the shuttle 16 may include acarrier 36 and two magnets 38, aligned concentrically and orientedback-to back with their opposing faces 40 having the same polarity. Assuch, they will exhibit a repelling force against each other. Theshuttle 16 may include an elastomer layer 42 disposed on each magnet'soutward face 44 and can provide a seal when the shuttle 16 is actuatedagainst either the first pressure orifice 24 or the second pressureorifice 26. The elastomer layer 42 may be constructed of a pliantmaterial which may include, for example, silicone and/or polyurethane.Each elastomer layer 42 may be retained in the shuttle 16 mechanically,for example, by portions of the shuttle 16 that overlap the edge of eachelastomer layer 42 and sandwich it to the corresponding magnet's outwardface 44. In other implementations, each elastomer layer 42 may beretained in the shuttle 16 by an adhesive holding the elastomer to eachmagnet's outward face 44. Alternatively, the elastomer layers 42 may besecured to each magnet's outward face 44 by way of overmolding theentire magnet 38 with the elastomer material, or applying a two-partelastomer material to the magnet 38. For example, each elastomer layer42 may be constructed by sandwiching each magnet 38 between two sheetsof elastomer material and melting portions of the sheets to each otherin order to create a pocket of elastomer in which each magnet 38resides. Optionally, the elastomer layer on one side of the shuttle 16may be thicker than the other side in order to decrease the sealingstability on the thicker side. This may be advantageous, for example,when a failsafe valve operation is desired, the thicker membraneallowing for easier disengagement of the shuttle from the port to beopened.

When a magnet is entirely overmolded by an elastomeric material, themagnet material optionally may first have the elastomeric materialovermolded onto it before magnetizing the magnet material. In otherexamples, the elastomeric overmolded material may comprise a magnetic(e.g. ferrite filled) material.

In some examples, the seal between the first or second pressure orifice24, 26 and the shuttle can be enhanced by the first or second pressurepost 28, 30 having a flat surface with rounded edges surrounding thefirst pressure orifice 24 and the second pressure orifice 26.Alternatively, the shuttle 16 may seal against a pressure post having aconical geometry surrounding the first pressure orifice 24 and thesecond pressure orifice 26. Optionally, the conical geometry of thepressure post may terminate with a flat surface with a width of about0.005 inches immediately surrounding both the first pressure orifice 24and the second pressure orifice 26. In some embodiments, the shuttle 16may seal against a pressure post having a hemispherical tip geometrysurrounding both the first pressure orifice 24 and the second pressureorifice 26.

In some embodiments, the carrier 36 of the shuttle 16 may include aguide element 46 and/or 48 having a cavity 50 enclosing each elastomerlayer 42 such that the guide cavity 50 envelopes a portion of both thefirst pressure post 28 or the second pressure post 30, depending onwhich is being sealed. In an exemplary embodiment, the guide elementsmay enclose or surround at least partially both pressure postsregardless of which is being sealed. This may be beneficial/desirable,for example, to maintain proper alignment of the shuttle 16 with eachpressure post 28, 30. Optionally, the guide elements 46, 48 may alsoinclude a plurality of air flow notches 52 that enable fluidcommunication between the valve cavity 32 and either the first pressureorifice 24 or the second pressure orifice 26, whichever is not beingsealed, by way of the corresponding guide cavity 50.

Optionally, the shuttle 16 magnets may be constructed to use theattractive magnetic force with each pressure post to maintain properalignment. In some cases, this may obviate the need for guide elements46 and/or 48.

In a shuttle having two magnets (such as that shown in FIG. 2A forexample), the distance between the two magnets of the shuttle may vary.For example, the distance or gap between the magnets of the shuttle maybe between about 0.0010″ and 0.0110″. In an exemplary embodiment, thedistance or gap may be about 0.0040″.

Referring now also to FIG. 2C, the magnetic flux path present in someembodiments of the shuttle 16 is shown. The magnets 38 may be orientedback-to-back with their opposing faces 40 having the same polarity, andas such, exhibit a repelling force against each other. When the magnets38 are oriented in this manner, a radial magnetic vector 39 is createdby the interaction of the magnets' respective flux leakage paths 29.These direct switching of the position of the shuttle 16 when theelectromagnetic coils 34 are sufficiently energized, as shown in FIG.2D. When the shuttle 16 is positioned against the second pressureorifice 26 and the electromagnetic coils 34 are energized such that theysupply an attractive magnetic force to the first pressure post 28 and arepellant magnetic force to the second pressure post 30, the fluxleakage paths 29 of the shuttle 16 will cause the attractive andrepellant magnetic forces of the posts 28, 30 to repel the shuttle 16away from the second pressure post 30 and attract it towards the firstpressure post 28.

Similarly, when the shuttle 16 is positioned against the first pressureorifice 24 and the electromagnetic coils 34 are energized such that theysupply an attractive magnetic force to the second pressure post 30 and arepellant magnetic force to the first pressure post 28, the flux leakagepaths 29 of the shuttle 16 will cause the attractive and repellantmagnetic forces of the posts to repel the shuttle 16 away from the firstpressure post 28 and attract it towards the second pressure post 30,positioning it against the second pressure orifice 26.

Referring now also to FIG. 2E, a ring plate 23 may optionally be used toassist in switching the position of the shuttle 16. In an example, thering plate 23 may be disposed around the shuttle 16 such that its inneredge 27 is in close proximity to the shuttle 16 in either sealingposition. When the first pressure post 28 and the second pressure post30 are energized such that they induce the shuttle 16 to switch sealingpositions, the ring plate 23 may help to focus the magnetic flux fromthe first pressure post 28 and the second pressure post 30 moreeffectively through the fasteners 17 and the outer plates 19 to assistin attracting one side of the shuttle 16 and repelling the opposite sideof the shuttle 16. This may assist in the shuttle 16 switchingpositions.

Referring now to FIGS. 2F and 2G, the shuttle 16 may optionally includelayers of elastomer 42, which in an example are retained to the magnetfaces 44 through mechanical retainers 41. Magnetic force from each ofthe pressure posts may help to maintain alignment of the shuttle and maynot require the use of any guide elements.

Referring now also to FIGS. 3A and 3B, the shuttle 54 may optionallyinclude a carrier 56 and two ring magnets 58, aligned concentrically andoriented back-to back with their opposing faces 59 having the samepolarity. As such, the two ring magnets 58 exhibit a repelling forceagainst each other. A layer of elastomer 60 or other material may alsobe disposed between the two ring magnets 58, so that the centralaperture 61 of one ring magnet is separated from the central aperture ofthe other.

Referring to FIGS. 4A and 4B, another example of the shuttle 62 mayinclude a carrier 64, with a plurality of magnets 66 arranged radiallyaround a central axis 76. Two central guide cavities 70 are alignedcoaxially with the central axis 76, one extending to a top surface 72and the other extending to a bottom surface 74. Each radially-orientedmagnet 66 is arranged to have a magnetization vector through itsthickness, giving the shuttle 62 an overall radial magnetization vector.Optionally, the shuttle 62 may further include a layer of elastomer 68or other material disposed in each of the central guide cavities 70. Insome embodiments, and as shown in FIG. 4D, two central guide cavities 70may be formed by positioning a layer of elastomer 69 in a centralchannel 71 that extends through the entire thickness of the shuttle 62such that the elastomer 69 bisects the channel 71 and fluidicallyseparates the top surface 72 from the bottom surface 74.

Referring to FIGS. 5A and 5B, in another example, the shuttle 78 mayinclude a carrier 80, comprising two or more concentrically-stackedlayers 82, each having a plurality of magnets 84 arranged radiallyaround a central axis 90. Each radially-oriented magnet 84 is arrangedto have a magnetization vector through its thickness, thereby giving theshuttle 78 an overall radial magnetization vector. The shuttle 78 mayinclude a central cavity 88 disposed along the central axis 90 andextending through the entire thickness of each layer 82. Optionally, theshuttle 78 may include a layer of elastomer 86 positioned between eachof the concentrically-stacked layers 82 and fluidically separating thecentral cavity 88 of one layer 82 from the central cavity 88 of anotherlayer 82.

Referring now to FIG. 5C, in some examples, the shuttle 78 may includetwo central guide cavities 92, aligned coaxially with a central axis 90,one extending into a top surface 96 of the shuttle 78, and the otherextending into a bottom surface 98 of the shuttle 78. Optionally, theshuttle 78 may also include a layer of elastomer 94 positioned in eachof the two central guide cavities 92.

In an alternate example, the shuttle 78 shown in FIGS. 5A and 5B maycomprise two shuttles 62 as shown in FIGS. 4A-4D that have been alignedcoaxially and mated together.

Referring now to FIG. 6A, in another example, the shuttle 100 mayinclude two magnets 104 oriented back-to-back and two posts 102extending from the outward faces 106 of each magnet 104. Each post 102is arranged so that when the bistable valve 13 is assembled, the posts102 may be disposed in both the first hollow post portion 28 and thesecond hollow post portion 30. This may eliminate the need for guideelements in the shuttle. Optionally, each post 102 has a cutout 108 tofacilitate fluid flow (pneumatic or hydraulic) from the unsealed orificeto the interior valve cavity.

As shown in FIGS. 6B and 6C, the post 103 may be constructed of anelastomer material and can seal against a shelf 105 within a cavity 107of the applicable post 109. In another example, the elastomer post 103shown in FIG. 6B may have a conical geometry, and seals against theshelf 105 within the cavity 107 which may be shaped to have a matingconical geometry as seen in FIG. 6C.

Referring now to FIG. 7 in another example, the shuttle 110 may beencased in a flexible membrane portion 112 and suspended or held inplace by a membrane portion 114 in an interior valve cavity 116. Themembrane portion 114 optionally may be perforated or fenestrated toallow pressure equalization in the interior valve cavity 116.Alternatively, the membrane portion 112 encasing the shuttle 110 may notbe perforated or fenestrated, and may act as a seal to prevent fluidcommunication between the interior valve cavity 116 and either a firstpressure orifice 118 or a second pressure orifice 120. In an alternativeconstruction, the membrane may be sandwiched between halves of theshuttle instead of enveloping the shuttle 110.

Referring now to FIG. 8 , a cross-sectional view showing another exampleof the shuttle 124 is shown. In this example, the shuttle 124 isactuated to seal either a first pressure orifice 126 or a secondpressure orifice 128 through the use of traditional wound-coilelectromagnets 122 instead of flat circuit board-based electromagneticcoils 34.

As shown in FIG. 9A, a valve manifold 130 may include an interior valvecavity 131, a first pressure inlet 132, a second pressure inlet 134, acantilever armature 146 constructed of a ferrous or magnetic material,at least two electromagnetic coils 144, and a common output orifice 148.The first pressure inlet 132 may include a first pressure post 136,which optionally may be constructed of a ferrous material, and extendsinto the interior valve cavity 131, the interior wall of the firstpressure post 136 defining a first pressure orifice 140. The firstpressure post 136 may be hollow so that the first pressure inlet 132 isin fluid communication with the interior valve cavity 131 via the firstpressure orifice 140. The second pressure inlet 134 may include a secondpressure post 138, which optionally may be constructed of a ferrousmaterial, and extends into the interior valve cavity 131 substantiallyopposite of the first pressure post 136, the interior wall of the secondpressure post 138 defining a second pressure orifice 142. The secondpressure post 138 may be hollow so that the second pressure inlet 134 isin fluid communication with the interior valve cavity 131 via the secondpressure orifice 142. The cantilever armature 146 may extend into theinterior valve cavity 131 so that it is disposed between the firstpressure orifice 140 and the second pressure orifice 142.

A first electromagnetic coil 144 may be positioned around the firstpressure post 136 so that when the coil 144 conducts a current, itenergizes the first pressure post 136, exerting an attractive force onthe cantilever armature 146. A second electromagnetic coil 144 may bepositioned around the second pressure post 138 so that, when the coil144 conducts a current, it energizes the second pressure post 138,exerting an attractive force on the cantilever armature 146.

The cantilever armature 146 may be either sealed against the firstpressure orifice 140 in a first position, or sealed against the secondpressure orifice 142 in a second position. In each sealing position, thearmature 146 is held in place by a continuous magnetic attraction fromthe armature 146 to either the energized first pressure post 136 or theenergized second pressure post 138, respectively, blocking fluidcommunication between the interior valve cavity 131 and thecorresponding first pressure orifice 140 or the second pressure orifice142. To switch the armature 146 from sealing against the first pressureorifice 140 to sealing against the second pressure orifice 142, theelectromagnetic coil 144 positioned around the first pressure post 136ceases to be energized and the electromagnetic coil 144 positionedaround the second pressure post 138 is energized so that it applies amagnetic force to the second pressure post 138 sufficient to attract thearmature 146 against the second pressure orifice 142. Similarly, toswitch the armature 146 from sealing against the second pressure orifice142 to sealing against the first pressure orifice 140, theelectromagnetic coil 144 positioned around the second pressure post 138ceases to be energized and the electromagnetic coil 144 positionedaround the first pressure post 136 is energized so that it applies amagnetic force to the first pressure post 136 sufficient to attract thearmature 146 against the first pressure orifice 140.

Referring now to FIG. 9B, the valve assembly shown in FIG. 9A furtherincludes a magnet 150 disposed on the cantilever armature 146 with themagnetic force vector 155 substantially aligned with an axis 152 definedby the first pressure post 136 and the second pressure post 138. In anexample, the valve system shown in FIG. 9B may function as a bistablevalve so that the electromagnetic coils do not need to continuouslyenergize the pressure post 136, 138 having the currently-sealed pressureorifice. The armature 146 is held against the sealed orifice 140, 142through a static magnetic attraction with the magnet 150.

Referring now to FIG. 9C, the valve assembly shown in FIG. 9A furtherincludes a magnet 154 disposed on the cantilever armature 146 with themagnetic force vector 156 substantially perpendicular to the axis 152.The arrangement in FIG. 9C may also function as a bistable valve.

In some embodiments, the valve may be actuated by passing a currentthrough an electromagnetic coil, whose magnetic flux acts on a ferrofluid.

In various embodiments, the bistable valve may be actuated by aplurality of arrays in which a first array comprises a row ofalternating polarity magnets, disposed adjacent to a second arraycomprising a row of alternating ferrous and non-ferrous material suchthat in one stable position, the ferrous material allows conductance ofone polarity of the magnets, and in a second stable position, the arrayshave shifted so the ferrous material allows conductance of the oppositepolarity of the magnets. Depending on the magnetic polarity beingconducted by the ferrous material, an adjacent ferrous or magnetic bodyis either pushed towards or pulled away from the plurality of arrays. Itis this action on the ferrous body that causes a first stable positionin the valve to occur or a second stable position in the valve to occur.By suspending the ferrous or magnetic body in an over-molded elastomer,a seal against one or more orifices can be obtained in either position.The arrays may be shifted by running a current through a plurality ofpiezoelectric crystals attached to each array. Alternatively, the arraysmay be shifted by other means/mechanisms/devices such as, for example,one or more of the following: servos, motors, solenoids, hydraulicmeans, pneumatic means, and/or NITINOL wire.

Optionally, the action of the above magnetic body may be used tocompress fluid in a closed system against a thin membrane that will thendeform into a bubble-like geometry. This action may be used to actuate avalve by sealing the deformed membrane against an orifice in oneposition and allowing fluid communication through the orifice inanother, non-deformed geometry.

In another example, the valve may be actuated using an electroactivepolymer. When current is passed through the electroactive polymer, thepolymer may expand in one direction while compressing in anotherdirection and allow an attached seal to separate from a valve orifice.This separation allows fluid communication through the valve from thatorifice. Terminating current flow through the electroactive polymerallows the electroactive polymer to return to its original shape,expanding in the direction in which it previously compressed, andcausing the attached seal to return to the valve orifice, blocking fluidcommunication from that orifice. Energizing the electroactive polymermay be accomplished by overmolding electrodes into contact with theelectroactive polymer. In some examples, the electroactive polymer maybe energized through the use of etched or printed electrodes orientedflat against the electroactive polymer. Multiple layers of theseelectrodes may be used to achieve optimal control of the electroactivepolymer.

FIG. 10A shows a perspective view of a plurality of bistable valves 13arranged in an array 158, wherein a valve manifold 20 incorporates theplurality of bistable valves 10. FIG. 10B shows a top view of a circuitboard 18 comprising multiple electromagnetic coils 34 for use in anarrangement of bistable valves 13 arranged in an array 158 as shown inFIG. 10A. FIG. 10C shows a cross-sectional view showing a plurality ofbistable valves 13 arranged in a valve array 158 and utilizing a commonvalve manifold 20, wherein the valve manifold 20 includes multipleinterior valve cavities 32.

Optionally, the electromagnetic coils 34 may be mounted in a flexiblecircuit board instead of a rigid circuit board. Each of the valve arraysmay include two or more bistable valves.

Referring now to FIG. 11A, one or more bistable valves 13 may beintegrated into a liquid flow control system 160. The bistable valve 13may be connected to a system manifold 162 in a vertical orientation suchthat the common output orifice 22 is in fluid communication with theflow control system pressure input 168. The flow control system 160 isconnected to a first pressure source 164 and a second pressure source166 for use in the bistable valve 13, for example, as shown in FIGS.1A-1D. The first pressure source 164 and the second pressure source 166may be integrated into a system manifold 162, or may be standalonecomponents to which the flow control system 160 can connect, or fromwhich it can be disconnected. In an embodiment, either the firstpressure source 164, the second pressure source 166, or both may providea common source of pressure to a plurality of valves (e.g., bistablevalves 13) integrated into a system manifold 162.

As shown in FIG. 11B, at least one bistable valve 13 may be integratedinto a liquid flow control system 160, or two or more bistable valves 13may be integrated into the system 160. The bistable valve 13 may bepositioned in a horizontal orientation and directly connected to thesystem manifold 162 so that the common output orifice 22 is in directfluid communication with the liquid flow control system's pressure input168. The system 160 may further include a first pressure source 170 anda second pressure source 172 for connection to the bistable valve 13 asshown in FIGS. 1A-1D. The first pressure source 170 and the secondpressure source 172 may be integrated into the system manifold 162, ormay be arranged as common lines to which individual valve modules ormanifold modules can be connected. Either the first pressure source 170,the second pressure source 172, or both may serve as a common pressuresource for one or a plurality of bistable valves 13 integrated into thesystem 160.

Referring now to FIGS. 12A and 12B, a plurality of bistable valves 13may be arranged in an array 180. This array 180 utilizes commoncomponents between the plurality of bistable valves 13, such as a valvemanifold comprising an first manifold half 182 and a second manifoldhalf 184. The first and second manifold halves 182, 184 define multipleinterior valve cavities 186, each interior valve cavity 186corresponding to one bistable valve assembly. Other common componentsmay include a first track 190 including a first track pressure rail 194and a second track 192 including a second track pressure rail 196. Thefirst track pressure rail 194 provides the same pressure input to eachof the first set of pressure input posts 198, each such pressure inputpost 198 connecting to one of the plurality of bistable valves 13 in thearray 180. Similarly, the second track pressure rail 196 provides thesame pressure input to each of the second set of pressure input posts200, each such pressure input post 200 connecting to one of theplurality of bistable valves 13 in the array 180. As seen in FIG. 12B,adjacent bistable valves 13 optionally may further share commonfasteners 188 constructed of a ferrous material, the fasteners beingintegral to the magnetic return path in the function of each bistablevalve 13 in the array 180.

In various embodiments, the first manifold half 182 and second manifoldhalf 184 may be ultrasonically welded together, for example, to createan airtight union between the two. Similarly, each of the first track190 and the second track 192 may be ultrasonically welded together tocreate an airtight union around the respective first track pressure rail194 and second track pressure rail 196. The valve manifold and each ofthe first track 190 and second track 192 components may then be joinedto each other using laser welding or other methods. As seen in FIG. 12B,the assembly optionally may include an outer plate 202 constructed of aferrous material. First and second outer plates 202 may be connected bya plurality of common fasteners 188, which also may comprise a ferrousmaterial.

Referring now to FIG. 13 , an outer plate 202 optionally may be fastenedto an array 180 of bistable valves. In the example shown, a plurality offasteners 188 surrounds each pressure post 204 of each valve in thearray. Optionally, each outer plate 202 may also include a plurality ofdirectional slits 206. The directional slits 206 can be arranged so thatthe magnetic flux paths of two adjacent valves are directed towardsdifferent fasteners 188 to help isolate each valve's function whenadjacent valves are actuated simultaneously. In an exemplaryimplementation, the actuation of adjacent valves can be staggered tooptimize each valve's magnetic flux path flow.

Referring now to FIGS. 14A-14C, another embodiment of a bistable valve1400 structure is shown. The valve 1400 includes an interior valvecavity 1420 defined by a first housing 1402, a second housing 1404, anda midbody 1406. Additionally, the valve 1400 includes a plurality of endplates 1408, a shuttle 1410, a first post 1412, a second post 1414,first pressure inlet 1416, a second pressure inlet 1418, and a commonoutput orifice 1422. Further, the bistable valve 1400 includes a firstelectromagnetic coil 1424 and a second electromagnetic coil 1426disposed around the first and second posts 1412 and 1414, respectively.In one example, the electromagnetic coils 1424 and 1426 may be flatelectromagnetic coils disposed in a printed circuit board (PCB), or theymay be vertically-oriented wire coils with wire leads as shown in FIG.14B. The common output orifice 1422 is in constant fluid communicationwith the valve cavity 1420, regardless of which position the valve isin. Conversely, the first and second pressure inlets 1416 and 1418 areeither in fluid communication with the interior valve cavity 1420, andthus, the common output orifice 1422, or they are sealed from fluidcommunication with the interior valve cavity 1420 by the shuttle 1410.When one of the two pressure inlets 1416 and 1418 is in fluidcommunication with the interior valve cavity, the other pressure inletis sealed by the shuttle 1410.

The first pressure inlet 1416 and the second pressure inlet 1418 may inone example extend through the same side of the valve 1400 as the commonoutput orifice 1422, as shown in FIG. 14B. Moreover, the first andsecond posts 1412 and 1414 may each have an additional pressure inlet1428 and 1430, respectively, as shown in FIG. 14C. The third pressureinlet 1428 may be in constant fluid communication with the firstpressure inlet 1416, while the fourth pressure inlet may be in constantfluid communication with the second pressure inlet 1418. In someembodiments, the valve 1400 may feature a third pressure inlet 1428 anda fourth pressure inlet 1430, each extending through their respectivefirst and second posts, without the additional first and second pressureinlets 1416 and 1418.

Referring now to FIGS. 15A-15B, in another example, a bistable valve1500 may include a shuttle 1502 comprising a magnet. The valve 1500 mayfurther include a first membrane portion 1508 abutting a first post1504, and a second membrane portion 1510 abutting a second post 1506,the first and second membrane portions 1508 and 1510, as well as theshuttle 1502 being disposed in an interior valve cavity 1516. The firstpost 1504 and the first membrane portion 1508 may be configured toprovide fluid communication from a first pressure inlet 1512 to theinterior valve cavity 1516 when the shuttle 1502 is not sealed againstthe first membrane portion 1508. Similarly, the second post 1506 and thesecond membrane portion 1510 may be configured to provide fluidcommunication from a second pressure inlet 1514 to the interior valvecavity 1516 when the shuttle 1502 is not sealed against the secondmembrane portion 1510. A common output orifice 1518 is in constant fluidcommunication with the interior valve cavity 1516, regardless of whichposition the shuttle 1502 is in. Conversely, the first and secondpressure inlets 1512 and 1514 are either in fluid communication with theinterior valve cavity 1516, and thus, the common output orifice 1518, orthey are sealed from fluid communication with the interior valve cavityby the shuttle 1502. When one of the two pressure inlets 1512, 1514 isin fluid communication with the interior valve cavity 1518, the otherpressure inlet is sealed by the shuttle 1502.

Referring now to FIGS. 16A-16B, in another example, a bistable valve1600 may include a shuttle 1602 comprising ferrous metal. The first post1604 and the second post 1606 are each magnets. The valve 1600 mayfurther include a first membrane portion 1608 abutting a first post1604, and a second membrane portion 1610 abutting a second post 1606,the first and second membrane portions 1608 and 1610, as well as theshuttle 1602 being disposed in an interior valve cavity 1616. The firstpost 1604 and the first membrane portion 1608 may be configured toprovide fluid communication from a first pressure inlet 1612 to theinterior valve cavity 1616 when the shuttle 1602 is not sealed againstthe first membrane portion 1608. Similarly, the second post 1606 and thesecond membrane portion 1610 may be configured to provide fluidcommunication from a second pressure inlet 1614 to the interior valvecavity 1616 when the shuttle 1602 is not sealed against the secondmembrane portion 1610. Output orifices 1618, 1620 are in constant fluidcommunication with the interior valve cavity 1616, regardless of whichposition the shuttle 1602 is in. Conversely, the first and secondpressure inlets 1612 and 1614 are either in fluid communication with theinterior valve cavity 1616, and thus, the output orifices 1618, 1620 orthey are sealed from fluid communication with the interior valve cavity1616 by the shuttle 1602. When one of the two pressure inlets 1612, 1614is in fluid communication with the interior valve cavity 1616, the otherpressure inlet is sealed by the shuttle 1602. In an exemplaryimplementation, as shown in FIG. 16B, the shuttle 1602 may be sphericalor spheroidal and may be made from any material as described above withrespect to various embodiments of the shuttle. The bistable valve 1600may include contact terminals 1622, 1624. A spherical or spheroidalshuttle can optionally be suspended in the interior valve cavity by anelastomeric membrane similar to the embodiment shown in FIG. 7 .

Referring now to FIGS. 17A-17E, a bistable valve 1700 in another examplemay include a shuttle 1702 comprising a magnet portion 1724. The shuttle1702 may further include a first membrane portion 1708 configured toabut a first post 1704, and a second membrane portion 1710 configured toabut a second post 1706, the first and second membrane portions 1708 and1710 attached to the magnet portion 1724, and the shuttle 1702 isdisposed in an interior valve cavity 1716. The first and second membraneportions 1708, 1710 may be attached to the magnet portion 1724 using anytype of adhesive, including, but not limited to, double sided tape, glueor other adhesive.

The first post 1704 and the first membrane portion 1708, which isattached to the magnet portion 1724, may be configured to provide fluidcommunication from a first pressure inlet 1712 to the interior valvecavity 1716 when the shuttle 1702 is not sealed against the first post1704. Similarly, the second post 1706 and the second membrane portion1710, which is attached to the magnet portion 1724, may be configured toprovide fluid communication from a second pressure inlet 1714 to theinterior valve cavity 1716 when the shuttle 1702 is not sealed againstthe second post 1706. Output orifices 1718, 1720 are in constant fluidcommunication with the interior valve cavity 1716, regardless of whichposition the shuttle 1702 is in. Conversely, the first and secondpressure inlets 1712 and 1714 are either in fluid communication with theinterior valve cavity 1716, and thus, the output orifices 1718, 1720 orthey are sealed from fluid communication with the interior valve cavityby the shuttle 1702. When one of the two pressure inlets 1712, 1714 isin fluid communication with the interior valve cavity 1716, the otherpressure inlet is sealed by the shuttle 1702. In an exemplaryconfiguration, the shuttle 1702 may be cylindrical and may be made fromany material as described above with respect to other versions of theshuttle. The bistable valve 1700 may include contact terminals 1721,1722 as well as coils 1726, 1728, end bodies 1730, 1732, and end plates1734, 1736 attached to the end bodies 1730, 1732.

The first and second posts 1704, 1706 shown in FIGS. 17B and 17E showtwo different configurations of pressure inlets 1712, 1714. In FIG. 17B,the first and second posts 1704, 1706 include a hole machined in,whereas, in FIG. 17E, the first and second posts 1704, 1706 include amachined groove, which is a slot and/or curve cut 1742, 1744.

Optionally, stabilizing features 1740 (FIG. 17E) may be added to themembrane and/or to the valve seat to assist in seating the shuttleproperly on the valve seat. Stabilizing features may include, forexample, bumps, nubs, posts, or other protuberances. Although not shownin all figures, stabilizing features may be included in any embodimentor version of a bistable valve assembly.

Referring now to FIGS. 18A-18B, a plurality of any of the variousconfigurations of a bistable valve may be combined into an array in amanifold assembly 1800. The array 1800 includes one or more bistablevalves having any of the shuttle 1802 configurations described herein.The manifold 1800 includes end plates 1804, 1806 and coil assemblies1808, surrounding the shuttles 1802 within the interior valve cavities1810.

A manifold assembly comprising bistable valves or valve systemsaccording to the various embodiments described may be used in manydifferent applications in which fluidic pressure (pneumatic orhydraulic) is used to drive pumps and/or valves in a device. Examplesinclude any liquid pumping apparatus such as a blood pump, hemodialysismachine, peritoneal dialysis machine, intravenous pump, or any liquidflow control device used in medical or industrial fields. Other usesinclude inflatable devices, such as a seat cushion. For example, amanifold assembly comprising bistable valves or valve systems can beused to inflate a seat cushion in a powered wheelchair, air bladders ina prosthetic device or other inflatable devices. A bistable valve orvalve system according to the various embodiments described may be usedin any application requiring the employment of a traditional standalonepneumatic or electronically-actuated valve.

The electromagnetic activation features described above may be appliedto a monostable valve as well. Instead of the shuttle having a first anda second pressure position, the monostable valve is configured to havean on and an off position with respect to one pressure source.

Referring now to FIGS. 19A-19B, various configurations of a bistablevalve may be integrated into various assemblies. In the example shown inFIGS. 19A-19B, a bistable valve 1906 is integrated into a regulator fora medical device, for example, a hemodialysis machine. A regulator PCB1900 is connected to the bistable valve 1906, and the apparatus includesoutlet tubing 1902, inlet tubing 1904, a pressure sensor 1910 and a PCBvalve adapter block 1908. In practice, one pressure inlet to the valvecavity is blocked and the pressure between the inlet tubing 1904 and theoutlet tubing 1902 is regulating by operation of the valve to make orbreak a connection between the two.

Referring now also to FIGS. 20A-20C, a bistable valve 2000 may include ashuttle comprising a magnet portion 2024. The shuttle may furtherinclude a first membrane portion 2008 which will abut a first post 2004,and a second membrane portion 2010 which will abut a second post 2006,the first and second membrane portions 2008 and 2010 attached to themagnet portion 2024, with the shuttle being disposed in an interiorvalve cavity 2016. The first post 2004 and the first membrane portion2008, which is attached to the magnet portion 2024, may be configured toprovide fluid communication from a first pressure inlet 2012 to theinterior valve cavity 2016 when the shuttle is not sealed against thefirst post 2004. Similarly, the second post 2006 and the second membraneportion 2010, which is attached to the magnet portion 2024, may beconfigured to provide fluid communication from a second pressure inlet2014 to the interior valve cavity 2016 when the shuttle is not sealedagainst the second post 2006. Output orifices 2018, 2020 are in constantfluid communication with the interior valve cavity 2016, regardless ofwhich position the shuttle is in. Conversely, the first and secondpressure inlets 2012 and 2014 are either in fluid communication with theinterior valve cavity 2016, and thus, the output orifices 2018, 2020 orthey are sealed from fluid communication with the interior valve cavity2016 by the shuttle. When one of the two pressure inlets 2012, 2014 isin fluid communication with the interior valve cavity 2016, the otherpressure inlet is sealed by the shuttle. In an example, the shuttle maybe cylindrical and made from any of the materials described above. Thebistable valve 2000 may include contact terminals 2022, 2023 as well ascoils 2026, 2028, end bodies 2030, 2032, and end plates 2034, 2036attached to the end bodies 2030, 2032. Optionally, the bistable valve2000 may also include at least one gasket seal 2038 and at least oneface seal 2040. Optionally, the bistable valve 2000 may also includelocating pins 2042, 2044 as well as a tie bar/screw 2046 and an end bodyhousing 2048. In some embodiments, the tie bar/screw 2046 attaches theend plates 2034, 2036 to the end body housing 2048. Other methods ofattachment may be used including adhesive, bolts, screws, pins, etc.

Referring now also to FIGS. 21A-21C, A bistable valve 2100 may include ashuttle 2102 comprising two opposing magnet portions 2124, 2125. Theshuttle 2102 may further include a first membrane portion 2108 attachedto the first magnet portion 2125 configured to abut a first post 2104,and a second membrane portion 2110 attached to the second magnet portion2124 configured to abut a second post 2106. The shuttle 2102 is disposedin an interior valve cavity 2116. The first post 2104 and the firstmembrane portion 2108, which is attached to the first magnet portion2125, may be configured to provide fluid communication from a firstpressure inlet 2112 to the interior valve cavity 2116 when the shuttle2102 is not sealed against the first post 2104. Similarly, the secondpost 2106 and the second membrane portion 2110, which is attached to thesecond magnet portion 2124, may be configured to provide fluidcommunication from a second pressure inlet 2114 to the interior valvecavity 2116 when the shuttle 2102 is not sealed against the second post2106. The first post 2104 and second post 2106 optionally may eachinclude a pneumatic port 2152, 2154. Output orifice 2118 is in constantfluid communication with the interior valve cavity 2116, regardless ofwhich position the shuttle 2102 is in. Conversely, the first and secondpressure inlets 2112 and 2114 are either in fluid communication with theinterior valve cavity 2116, and thus, the output orifice 2118 or theyare sealed from fluid communication with the interior valve cavity 2116by the shuttle 2102. When one of the two pressure inlets 2112, 2114 isin fluid communication with the interior valve cavity 2116, the otherpressure inlet is sealed by the shuttle 2102. In one example, theshuttle may be cylindrical and made from any of the materials describedabove with respect to various shuttles. The bistable valve 2100 mayinclude contact terminals 2122, 2123 as well as coils 2126, 2128, endbodies 2130, 2132, and end plates 2134, 2136 attached to the end bodies2130, 2132. Optionally, the bistable valve 2100 may also include atleast one gasket seal 2138 and at least one face seal 2140. In anexemplary configuration, the bistable valve 2100 may also includelocating pins as well as a tie bar/screw (not shown) and an end-bodyhousing 2148. The tie bar/screw attaches the end plates 2134, 2136 tothe end body housing 2148. Other methods of attachment may also be usedincluding adhesive, bolts, screws, pins, etc.

Any of the magnets shown as part of the shuttle may comprise stackedmagnets: more than one magnet forms the magnetic portion of the shuttle.Various sizes, shapes and thicknesses of the magnet may alter itsmagnetic force, whether opposing or attracting.

FIG. 22 depicts a representational view of an interior cavity 2200 of anexample bistable valve. As shown, a shuttle 2202 is positioned in theinterior cavity 2200. The shuttle 2202 includes a magnet 2204 which isovermolded with an elastomeric material 2206. In some configurations,multiple magnets may be enveloped by the overmolded elastomeric material2206. Any of the shuttles such as any of those described in FIGS. 2A-5Cmay be similarly overmolded.

The elastomeric material 2206 also includes a number of radial arms oroffshoots 2208 which extend from the magnet 2204 to the walls of theinterior cavity 2200. These radial offshoots 2208 may serve to hold themagnet 2204 substantially along the central axis of the interior cavity2200 and may inhibit rotation of the magnet 2204. The radial offshoots2208 may also act as a damper during actuation of a valve, which mayhelp to minimize the acoustic noise generated as the shuttle 2202 isdisplaced or toggled back and forth.

In the example embodiment, the elastomeric radial offshoots 2208 roughlyresemble the arms of a cross, though they may be of any convenient shapeand/or any number. For example the radial offshoots 2208 may bespoke-like. The amount of open space between each of the radialoffshoots 2208 may also vary. In an exemplary manufacturing process, theradial offshoots 2208 may be laser cut out of a larger piece ofelastomeric material. In an alternate arrangement, instead of radialoffshoots 2208, the magnet 2204 may be kept in place by a web-likediaphragm. Such a diaphragm may include a number of generally concentricrings of elastomeric material connected to a number of radial offshootsextending outwardly from the magnet 2204. In such an embodiment,pressure would be allowed to equalize on each side of the shuttle 2202through the openings in the web-like diaphragm.

In various embodiments of the various bistable valves described herein,the coil may be PCB-based flat coils (i.e., coils on a printed circuitboard) or wire wound coils. The coils may be potted into a valveassembly. Any suitable potting material, such as a low Q material may beused. This may help to reduce acoustic noise generated during operationof a valve. It may also help to make the magnetic coil reliability morerobust.

Wound wire coils may have an air core. Optionally, the coils may bewound around a supporting structure. This may help to simplifymanufacture and assembly of a coil and a valve. Any suitable supportingstructure may be used, such as a spool, reel, or bobbin. The supportingstructure may also have one or more coupling or engagement features thathelp to simplify installation of the coil into a bistable valve. Forexample, a supporting structure may include a snap fit feature or aguide feature which interacts with a complementary feature of thebistable valve. Such interaction may ensure that a coil is seated in adesired or prescribed orientation in the valve assembly. The supportstructure may also be dimensioned and/or made of a material which helpsto generate a desired magnetic flux path.

An example coil assembly 2300 is shown in FIG. 23 . The coil assembly2300 includes a bobbin 2302. The bobbin 2302 may be made from anysuitable material and may, for example, be a molded part made frominjection molded plastic. The coil may be wound around the bobbin 2302so that a magnetic field is created when current passes through thewire. Two leads 2306 which are attached to respective contacts 2308 arealso shown in FIG. 23 . The contacts 2308 may be contact pins as shown,or the contacts 2308 may include a pad or strip that allows for greatertolerances when assembling a bistable valve.

FIG. 24 depicts an example embodiment of a bistable valve 3900. Asshown, the bistable valve 3900 includes optional conductive or metalstrips 3902A-C which may be placed or crimped onto the contacts 3908.Alternatively, the metal strips may be attached (e.g soldered) orintegral with the contacts 3908. The metal strips 3902A-C may allow alarger contact area/patch when placing a current source intocommunication with the valve 3900. This may obviate the need to alignpin contacts with a connector on the current source, simplifyingassembly and allowing for larger tolerances. As shown, one of the metalstrips 3902C connects a contact 3908 from one coil assembly 3904 to acontact on another coil assembly 3908. The other two metal strips 3902A,B may act as positive/negative terminals for the coils depending on thedesired direction of current flow through the coil assemblies 3904. Themetal strips 3902A-C may be made of any suitable material such as, forexample, copper.

Referring now to FIGS. 25A-25C, in some embodiments, a bistable valve2400 may include a shuttle 2402 comprising a magnet 2425. The shuttle2402 may further include a first membrane portion 2408 attached to afirst face of the magnet 2425. The shuttle 2402 may also include asecond membrane portion 2410 attached to a second face of the magnet2425 which is opposite the first face. The shuttle 2402 is disposed inan interior valve cavity 2416. The bistable valve 2400 also includes afirst post 2404 and a second post 2406. The first post 2404 and secondpost 2406 may act to direct magnetic flux pathways within the bistablevalve 2400. The first post 2404 and second post 2406 may also act ascores for the electromagnetic coils 2426, 2428 of the bistable valve2400. The first post and second post may be made from a material with adesired magnetic permeability.

The example embodiment in FIGS. 25A-25C includes a plurality of outputorifices. As shown, the bistable valve 2400 embodiment includes a firstoutput orifice 2418 and a second output orifice 2419. When the shuttle2402 is sealing over a first pressure inlet 2412, the first outputorifice 2418 and second output orifice 2419 are placed into fluidcommunication with a second pressure inlet 2414 through the interiorvalve cavity 2416. When the shuttle 2402 is sealing over the secondpressure inlet 2414, the first output orifice 2418 and second outputorifice 2419 are placed into fluid communication with the first pressureinlet 2412. When one of the two pressure inlets 2412, 2414 is in fluidcommunication with the interior valve cavity 2416, the other pressureinlet is sealed by the shuttle 2402. In various embodiments, the shuttle2402 may be cylindrical and may be made from any material as describedabove with respect to various embodiments of the shuttle. The firstoutput orifice 2418 and second output orifice 2419 may connect to acommon fluid line or may each be connected to separate and isolatedfluid lines in various embodiments. In the example embodiment, thepressure inlets 2412, 2414 are not included in or part of the first andsecond posts 2404 and 2406. This may help to simplify manufacturing ofthe bistable valve 2400.

In various embodiments, a bistable valve 2400 may include valve bodies2430, 2432. These valve bodies 2430, 2432 may be coupled together toform the various flow paths and cavities of the bistable valve 2400. Thevalve bodies 2430, 2432 may be molded parts which include voids for thepressure inlets 2412, 2414, the interior valve cavity 2416, and theoutput orifices 2418, 2419. The valve bodies 2430, 2432 may be coupledtogether in any suitable manner which creates sealed flow paths forfluid passing through the bistable valve 2400.

In various embodiments, a bistable valve 2400 may include contactterminals 2422, 2423 as well as coils 2426, 2428. As shown, the coils2426, 2428 may be included on a coil assembly 2450 which is placed intoa receiving structure in the valve bodies 2430, 2432 during assembly. Inthe example embodiments, the coils 2426, 2428 are included onbobbin-like coil assemblies 2450 similar to that depicted in FIG. 23 .

The bistable valve 2400 shown in FIGS. 25A-C also includes end plates2434, 2436 which are attached to the valve bodies 2430, 2432. One ormore fastener 2444 may pass through or couple into the end plates 2434,2436, and may help to hold the valve bodies 2430, 2432 together. Asdescribed elsewhere, any suitable type of fastener may be used. Forexample, the fastener may be a bolt, screw, rivet, etc. In variousembodiments, the bistable valve 2400 may also include at least onegasket or sealing member which may be any type of seal. In variousembodiments, the bistable valve 2400 may also include locating pins2440, 2442.

FIGS. 26A-26C depict another embodiment of a bistable valve assembly3800. The bistable valve assembly 3800 includes a shuttle 3802 made of amagnetized material. The shuttle 3802 is disposed in an interior valvecavity 3816. The bistable valve 3800 includes a first post 3804 and asecond post 3806. The first post 3804 and second post 3806 areconfigured to direct magnetic flux pathways within the bistable valve3800. The first post 3804 and second post 3806 may also act as cores forthe electromagnetic coils 3826, 3828 of the bistable valve 3800.

As best shown in FIG. 26C, two inserts 3880 may be included in abistable valve assembly 3800, or in any other type of valve assembly inwhich a moving shuttle is used to mechanically block or opencommunication between an inlet of the valve assembly and the valvecavity. When assembled, these inserts 3880 surround the shuttle 3802 andfit within the interior valve cavity 3816. In an exemplary construction,the inserts 3880 have a substantially cup-like shape.

The inserts 3880 may be made of an elastomeric or other soft orcompliant material. For example, the inserts 3880 may be made of Viton®or a similar material. The inserts may also be molded fromsound-absorbing plastics that, when formed and solidified, provide bothsoundproofing qualities as well as structural support to withstandrepeated movement of a shuttle within the insert. The inserts 3880 mayhelp to dampen any noise generated as the valve toggles betweenpositions and may allow for better sealing of the shuttle 3802 overpressure inlets 3812, 3814. Thus the inserts may eliminate a need for aseparate flexible or elastomeric membrane on either the shuttle face orthe valve seat to achieve a seal between the valve seat and the surfaceof the shuttle.

Each of the inserts 3880 may include a sealing flange 3882. Whenassembled, the sealing flanges 3882 abut and compress against eachother. The valve bodies 3840, 3842 can be coupled together to form thebistable valve 3800 by means of one or more fasteners 3844 passingthrough end plates 3834 and 3836. As best shown in FIG. 26B, mating ormutual compression of the flanges 3882 may fluidically seal the interiorvalve cavity 3816 as the two valve bodies 3840, 3842 of the bistablevalve 3800 are joined together.

The example embodiment in FIGS. 26A-26C includes one or more pressureinlets 3812, 3814 and output orifices 3818, 3819. The pressure inlets3812, 3814 and output orifices 3818, 3819 are formed as part of thevalve bodies 3840, 3842. As shown, the bistable valve assembly 3800includes a first output orifice 2418 and a second output orifice 2419.It also includes a first pressure inlet 3812 and a second pressure inlet3814. The inserts 3880 include fluid pathways 3884, 3886 which extendthrough the inserts 3880. First pressure inlet 3812 and second pressureinlet 3814 align with fluid pathways 3886 of their respective inserts3880. The first fluid output orifice 3818 and second fluid outputorifice 3819 align with fluid pathways 3884 of their respective insert3880. Each insert 3880 may also include a valve seat 3888 against whichthe shuttle 3802 may form a seal.

When the shuttle 3802 is sealing the valve seat 3888 of first pressureinlet 3812, the first output orifice 3818 and second output orifice 3819are placed into fluid communication with a second pressure inlet 3814through the interior valve cavity 3816. When the shuttle 3802 is sealingthe valve seat 3888 of the second pressure inlet 3814, the first outputorifice 3818 and second output orifice 3819 are placed into fluidcommunication with the first pressure inlet 3812. When one of the twopressure inlets 3812, 3814 is in fluid communication with the interiorvalve cavity 3816, the other pressure inlet is sealed by the shuttle3802. In some examples, the shuttle 3802 is cylindrical and may be madefrom any material as described above with respect to other examples ofthe shuttle. The first output orifice 3818 and second output orifice3819 can be configured to connect to a common fluid line or may each beconnected to separate and isolated fluid lines, depending on the desiredapplication. Optionally, the pressure inlets 3812, 3814 are not includedin or part of the first and second posts 3804 and 3806. This may help tosimplify manufacturing of the bistable valve assembly 3800. Optionally,the inserts 3880 may include an asymmetric feature that allows theinserts 3880 to be installed in the bistable valve 3800 in only aparticular orientation. The asymmetric feature may for example ensurethat the inserts 3880 are installed in a manner in which fluid pathways3884, 3886 align with the pressure inlets 3812, 3814 and output orifices3818, 3819, helping to simply assembly of the bistable valve 3800.

A bistable valve assembly 3800 may include contact terminals 3822, 3823as well as coils 3826, 3828. As shown, the coils 3826, 3828 may bemounted on a coil assembly 3850 that can be placed into a receivingstructure in the valve bodies 3840, 3842 during assembly. In the exampleshown, the coils 3826, 3828 are wound on bobbin-like coil assemblies3850 similar to that depicted in FIG. 23 .

FIGS. 27A-27D depict another embodiment of a bistable valve 4000. Thebistable valve 4000 may include a shuttle 4002, that can be made of amagnetized material. The shuttle 4002 is disposed in an interior valvecavity 4016. The bistable valve 4000 may also include a first post 4004and a second post 4006. The first post 4004 and second post 4006 may actto direct magnetic flux pathways within the bistable valve 4000. Thefirst post 4004 and second post 4006 may also act as cores for theelectromagnetic coils 4026, 4028 of the bistable valve 4000. In anexemplary configuration, a bistable valve 4000 may include contactterminals 4022, 4023 connected to coils 4026, 4028. As shown, the coils4026, 4028 may be included on a coil assembly 4050 which is placed intoa receiving structure in the valve bodies 4040, 4042 during assembly. Inthe example shown, the coils 4026, 4028 are wound on bobbin-like coilassemblies 4050 similar to that depicted in FIG. 23 .

As best shown in FIG. 27C, two inserts 4080 may be included in abistable valve 4000. The inserts 4080 include a cavity portion 4090.When assembled, the cavity portion 4090 of each insert 4080 maycooperatively surround the shuttle 4002 and define the interior valvecavity 4016. The inserts 4080 may be made of an elastomeric or othercompliant material such as Viton or comparable material. This type ofmaterial may allow the inserts 4080 to dampen noise generated as thevalve toggles back and forth, and may allow for better sealing of theshuttle 4002 over pressure inlets 4012, 4014. In the example embodiment,the inserts 4080 also include the pressure inlets and outlets for thevalve 4000, which tends to simplify manufacturing of the valve assembly.As shown, pressure inlets 4012, 4014 and output orifice 4018, 4019 aremolded as part of each insert 4080. All inserts 4080 can be designed tohave uniform dimensions and features, allowing them to be manufacturedusing the same mold.

Each of the inserts 4080 may include a sealing flange 4082. Whenassembled, the sealing flanges 4082 can abut and compress against eachother. The valve bodies 4040, 4042 can be coupled together to form thebistable valve assembly 4000 by using one or more fasteners 4044 passingthrough end plates 4034, 4036. As best shown in FIG. 27B, abutmentand/or mutual compression of the flanges 4082 may fluidically seal theinterior valve cavity 4016 as the two valve bodies 4040, 4042 of thebistable valve 4000 are joined together.

FIG. 27D depicts a cross sectional view taken through the cavity portionof an insert 4080. As shown, the insert includes a valve seat 4088surrounding the first pressure inlet 4012. Surrounding the valve seat4088 are a number of raised elements 4092. The raised elements 4092 canbe arranged to circumferentially surround the valve seat 4088 (e.g.continuously or at spaced angular intervals). The valve seat 4088 isslightly proud of the raised elements 4092. When the shuttle 4002 is ina sealing position over the valve seat 4088, the shuttle 4002 may beretained in that position via magnetic attraction. This magneticattraction may cause some compression of the valve seat 4088 material.The height difference between the valve seat 4088 and the raisedelements 4092 can be chosen so that the expected compression of thevalve seat 4088 places it at substantially even height with the raisedelements 4092. As a result, the shuttle 4002 can rest on both the valveseat and the surrounding raised elements 4092. The raised elements 4092may help to support the edges of the shuttle 4002 and encourage it tosit flat against the valve seat 4088, helping optimize the seal created.

Referring back to FIG. 27B, when the shuttle 4002 is positioned againstthe valve seat 4088 of first pressure inlet 4012, the first outputorifice 4018 and second output orifice 4019 are placed into fluidcommunication with a second pressure inlet 4014 through the interiorvalve cavity 4016. When the shuttle 4002 is positioned against valveseat 4088 of the second pressure inlet 4014, the first output orifice4018 and second output orifice 4019 are placed into fluid communicationwith the first pressure inlet 4012. When one of the two pressure inlets4012, 4014 is in fluid communication with the interior valve cavity4016, the other pressure inlet is sealed by the shuttle 4002.

FIGS. 28A-28D depict another embodiment of a bistable valve assembly4100. The bistable valve assembly 4100 includes a shuttle 4102preferably made of a magnetized material. The shuttle 4102 is disposedin an interior valve cavity 4116. The bistable valve assembly 4100 alsoincludes a first post 4104 and a second post 4106. The first post 4104and second post 4106 act to direct magnetic flux pathways within thebistable valve assembly 4100. The first post 4104 and second post 4106also act as cores for the electromagnetic coils 4126, 4128 of thebistable valve assembly 4100. An exemplary bistable valve assembly 4100may include contact terminals 4122, 4123 connected to coils 4126, 4128.As shown, the coils 4126, 4128 may be included on a coil assembly 4150which is placed into a receiving structure in the valve bodies 4140,4142 during assembly. In the example embodiments, the coils 4126, 4128are wound on bobbin-like coil assemblies 4150 similar to that depictedin FIG. 23 .

The example embodiment in FIGS. 28A-28D includes a plurality of outputorifices. As shown, the bistable valve assembly 4100 includes a firstoutput orifice 4118 and a second output orifice 4119. When the shuttle4102 is positioned over a first pressure inlet 4112, the first outputorifice 4118 and second output orifice 4119 are placed into fluidcommunication with a second pressure inlet 4114 through the interiorvalve cavity 4116. When the shuttle 4102 is positioned over the secondpressure inlet 4114, the first output orifice 4118 and second outputorifice 4119 are placed into fluid communication with the first pressureinlet 4112. When one of the two pressure inlets 4112, 4114 is in fluidcommunication with the interior valve cavity 4116, the other pressureinlet is sealed by the shuttle 4102. An exemplary shuttle 4102 may becylindrical and may be made from any material as described above withrespect to various configurations of the shuttle. The first outputorifice 4118 and second output orifice 4119 may connect to a commonfluid line, or may each be connected to separate and isolated fluidlines, depending on the desired application. In the example shown, thepressure inlets 4112, 4114 are not included in or part of the first andsecond posts 4104 and 4106, which may help to simplify manufacturing ofthe bistable valve assembly 4100.

As best shown in FIG. 28C, a valve assembly such as the bistable valveassembly 4100 may use a monolithic gasket 4180 to simplify constructionof the valve assembly. The monolithic gasket 4180 is shown in greaterdetail in FIG. 28D. The monolithic gasket 4180 includes a loop portion4182 which is coupled to an input/output seal portion 4184 by aconnecting region 4186. During assembly the valve bodies 4140, 4142 arecoupled together to form the bistable valve assembly 4100 by passing oneor more fasteners 4144 through end plates 4134. As best shown in FIG.28B, compression of the loop portion 4182 may fluidically seal theinterior valve cavity 4116 as the two valve bodies 4140, 4142 of thebistable valve 4100 are joined together. The loop portion 4182 maydiffer in shape depending on the geometry of the shuttle 4102 and otherinternal components, with the shape additionally being chosen based onthe cross-sectional dimension of the interior valve cavity 4116. Theinput/output seal portion 4184 is configured to seal against a manifoldinto which the valve assembly 4100 is installed. By molding each sealingmember together as a monolithic gasket 4180, part count can be reducedand manufacturing/assembly is simplified.

In some embodiments, a bistable valve such as or similar to any of thosedescribed herein may be modified to create a mono-stable valve. FIGS.29A-29C depict an example mono-stable valve 2500 embodiment. As shown,the mono-stable valve 2500 includes a shuttle 2502 comprising a magnet2525. The shuttle 2502 may further include a first membrane portion 2508attached to a first face of the magnet 2525. The shuttle 2502 may alsoinclude a second membrane portion 2510 attached to an opposite, secondface of the magnet 2525. The shuttle 2502 is disposed in an interiorvalve cavity 2516. The example embodiment shown in FIGS. 29A-C includesa first post 2104 only a single electromagnetic coil 2526. The coil 2526may be supported on a bobbin-like support structure 2528 as best shownin FIGS. 29B-C.

Various embodiments, a mono-stable valve 2500 may include contactterminals 2522, 2523 (best shown in FIGS. 29B-C). In the example, thecontact terminal 2522, 2523 are pad-like which as mentioned above, mayallow for more forgiving tolerances. The example mono-stable valveincludes two valve bodies 2530, 2532 similar to those shown in FIGS.25A-C. End plates 2534, 2536, attached to the valve bodies 2530, 2532are also included. A fastener 2550 may be used to couple the valvebodies 2530, 2532 and end plates 2534, 2536 together. In various otherembodiments, any suitable method of attachment or coupling may be usedin place of a fastener 2550 including adhesive, chemical bonding, RFwelding, etc.

In a first position (shown in FIG. 29A) of the shuttle 2502, the firstmembrane portion 2508, which is attached to the magnet 2525, may beconfigured to create a seal over a first pressure inlet 2512. In thisposition, fluid communication from the first pressure inlet 2512 to theinterior valve cavity 2516 is blocked. In the first position, fluidcommunication from a second pressure inlet 2514 into the interior valvecavity 2116 may occur. In a second position, the magnet 2525 may beconfigured to seal over the second pressure inlet 2514. In thisposition, fluid communication from the second pressure inlet 2514 intothe interior valve cavity 2516 is blocked. In the second position, fluidcommunication from the first pressure inlet 2512 into the interior valvecavity 2516 may occur. As described elsewhere herein, fluid may becommunicated from the interior valve cavity 2516 to one or more outputorifice 2518.

In the example embodiment, the shuttle 2502 is stable in the firstposition. In the first position, the shuttle 2502 is held in place bystatic magnetic attraction. To transition the mono-stable valve 2500from the first position to the second position, the coil 2526 may beappropriately energized to repel the magnet 2525 in the shuttle 2502such that the shuttle 2502 displaces from a sealing position over thefirst inlet 2512 to a sealing position over the second inlet 2514. Aholding current may be supplied to the coil to keep the shuttle 2502sealed against the second inlet 2514. Current may then be passed throughthe coil 2526 in the opposite direction to attract the shuttle 2502 suchthat the shuttle 2502 displaces back to the first position. In analternative embodiment shown in FIG. 29D, a second post 2506 may beincluded. The second post 2506 may help to lower the holding currentnecessary to hold the shuttle 2502 in the second position. Such anembodiment may also generate less heat during operation.

FIGS. 30A-30E depict an example of a bi-stable 2 way valve assembly3700. Such a valve 3700 may not require a holding current when operated.The example embodiment shown in FIGS. 30A-30E includes a first post 3712and an electromagnetic coil 3726. The coil 3726 may be supported on abobbin-like support structure 3728 as shown in FIGS. 30B and 30C. Thevalve assembly 3700 may include contact terminals 3722, 3723 (best shownin FIG. 30B) for supplying current to the electromagnetic coil 3726 froman external source. The example valve assembly 3700 includes a valvebody 3730, an input/output body 3732 and end plates 3734, 3736. Afastener 3750 may be used to couple the valve body 3730, input/outputbody 3732 and end plates 3734, 3736 together. Rather than a fastener3750, other methods of coupling may include use of an adhesive, chemicalbonding, RF welding, etc. A sealing gasket 3738 may be compressedbetween the valve body 3730 and the input/output body 3732 when thevalve 3700 is assembled.

As shown, the valve assembly 3700 includes a shuttle 3702 that includesa magnet 3725. The shuttle 3702 is disposed in an interior valve cavity3716. The shuttle 3702 may further include a membrane portion 3708, inaddition to a shuttle body 3706. The shuttle body 3706 has a shuttleface 3704 to which the membrane portion 3708 is attached. The membraneportion 3708 may be attached in any suitable manner. For example, themembrane portion 3708 may be overmolded to the shuttle face 3704. Theshuttle body 3706 may also include a shuttle stem 3710. The magnet 3725may be ring or O shaped with a substantially central opening sized sothat the magnet 3725 may be slid over the shuttle stem 3710 and attachedto the shuttle body 3706.

A biasing member 3714 may also be included in the interior valve cavity3716. The biasing member 3714 in the example shown is a compressionspring. The biasing member 3714 is seated against a wall of the interiorvalve cavity 3716 opposite the valve seat 3718 and contacts a surface ofa flange 3724 on the shuttle body 3706. The biasing member 3714 appliesa biasing force on the shuttle 3702 to a first position within theinterior valve cavity 3716.

In a first position (shown in FIG. 30D) of the shuttle 3702, the firstmembrane portion 3708, is configured to press against and create a sealover a valve seat 3718. In this position, fluid communication from apressure inlet 3713 to the interior valve cavity 3716 is blocked. In thefirst position, a pressure outlet 3715 is in fluid communication withthe interior valve cavity 3716. In a second position, the shuttle 3702is displaced away from the valve seat 3718. In this position, fluidcommunication between the pressure inlet 3715 and the pressure outlet3715 via the interior valve cavity 3716 is established.

In the example shown, the shuttle 3702 is stable in the first positiondue to the biasing force exerted by the biasing member 3714. Optionally,the shuttle may be stabilized in the first position by the addition of amagnet to provide magnetic attraction between the shuttle 3702 and theinput/output body 3723 and/or end plate 3736. To transition the valve3700 from the first position to the second position (FIG. 30E), the coil3726 can be energized to attract the magnet 3725 in the shuttle 3702 sothat the shuttle 3702 is no longer in a sealing position over the valveseat 3718. The electromagnetic attraction is sufficient to overcome thebiasing force of the biasing member 3714. The shuttle 3702 can then beretained in the position against the restoring force of the bias member3714 by the magnet's 3725 magnetic attraction with the first post 3712.Thus a holding current is not necessary to hold the shuttle 3702 ineither the first or second positions. Current may be passed through thecoil 3726 in the opposite direction to repel the shuttle 3702 such thatthe shuttle 3702 displaces back to the first position.

Shuttle Constraining Features

In some embodiments, a bistable valve such as, though not limited to anyof those described herein may include one or more feature(s) which serveto constrain the shuttle about one or more degrees of freedom. This mayhelp to ensure that a magnet of the shuttle has its poles oriented in aprescribed manner. It may help to ensure that the shuttle willrepeatedly and reproducibly make a proper seal on the fluid inlets to aninterior valve cavity. Additionally, a constraining feature may helpsimplify assembly of a bistable valve since a constraining feature mayhelp to ensure that a shuttle can only be installed in the valve in aproper orientation. In some specific embodiments, all but one degree offreedom of the shuttle may be substantially constrained. For example,all of the shuttle's rotational degrees of freedom may be constrainedwhile all but one of the shuttles translational degrees of freedom maybe constrained. The translational degree of freedom which is notconstrained may be a degree of freedom which allows the shuttle todisplace about the axis of the interior valve cavity.

In some embodiments, a shuttle may have one or more keyed alignmentfeatures that serve as a constraining feature. Each of the one or morekeyed alignment features cooperate with the interior valve cavity toconstrain the shuttle to the desired degrees of freedom. A keyedalignment feature may take any of a variety of forms. For example, thecross sectional shape of a shuttle may be chosen to inhibit motion aboutunwanted degrees of freedom. A shuttle may be polygonal, ovoid, orirregularly shaped and may displace within a cooperatively shapedinterior valve cavity. Alternatively, the interior valve cavity mayinclude one or more guide projection which extends from the wall of theinterior valve cavity into the volume of the interior valve cavity. Eachguide projection may fit into a respective corresponding recess in theshuttle and serve to constrain the shuttle from undesired movement. Theguide projection may or may not be dovetailed depending on theembodiment. The keyed alignment feature used may be selected so as toprovide suitable magnetic flux paths within a bistable valve.Alternatively, the keyed alignment feature may not be a continuous partof the magnet of the shuttle. For example, the keyed alignment featuremay be a non ferrous or non-magnetic insert or attachment which iscoupled into, onto, or around the magnet. Such an insert or attachmentmay be made of any suitable metal of plastic. In embodiments with aplurality of magnets, the keyed alignment feature may be included on apiece of material which is captured or retained between two of themagnets of the shuttle. Alternatively, the piece of material includingthe keyed alignment feature may as serve to retain the magnets of theshuttle. The keyed alignment feature may or may not extend through theentire thickness of the shuttle.

In other embodiments, such as the embodiment depicted in FIGS. 31 , theshuttle 2602 of a bistable valve 2600 may include a guide or tabprojection 2604. This projection 2604 may fit into a correspondingrecess 2606 in the side wall of the interior valve cavity 2608. Therecess 2606 may include rollers or ball bearings (not shown) in someembodiments to minimize friction. As mentioned above, this guide tab orprojection 2604 may be dovetailed although in the example embodiment, adovetailed feature is not present. As shown, the guide tab or projection2604 would substantially prevent yawing of the shuttle 2602. Thefootprint of the interior valve cavity 2608 is only slightly larger thanthe footprint of the shuttle 2602. Due to the thickness of the shuttle2602, the interior valve cavity 2608 will substantially prevent roll andpitching of the shuttle 2602. The footprint of the interior valve cavity2608 will also substantially prevent translational displacement of theshuttle 2602 in directions other then the axial direction of theinterior valve cavity 2608.

FIGS. 32A-32C depict an example shuttle 2700 which includes a number ofkeyed alignment features 2702. As shown, the keyed features 2702 aresmall pegs which project outwardly from a magnet retaining structure2704 of the shuttle 2700. As best shown in FIG. 32C, two crown members2706 may be placed over the ends of the magnet retaining structure tohold the magnets 2708 in place in the magnet retaining structure 2704.The crown members 2706 may also each capture a piece of pliant material2710 against the magnet retaining structure 2704 when the shuttle 2700is assembled. The crown members 2706 may be held in place by anysuitable means. For example, the crown members 2706 may be solventbonded, glued, high frequency welded, ultrasonically welded, etc. ontothe magnet retaining structure 2704. The pegs extend outwardly from themagnet retaining structure 2704 such that the width of the shuttle 2700is greatest at the location of the pegs. Thus the shuttle 2700 may ridealong peg receiving tracks in an interior valve cavity and besubstantially restrained from undesired movement. In alternateembodiments, it should be noted that the keyed feature may be aprojection from any other part of a shuttle. For example, the keyedfeature may be a projection on one or both of the crown members 2706 ofa shuttle.

FIGS. 33A-33C depict an example embodiment of shuttle 3600 including anumber of notches 3602A, B which act as constraining features. Thenotches 3602A, B may be formed in an overmolded coat 3604 which covers amagnetic or metal body 3606 of the shuttle 3600. The overmolded coat3604 optionally, either in whole or in part, is made of an elastomericmaterial which may further help to ensure that a proper seal is madeover valve seats of a valve as it is toggled between positions. As shownthe notches 3602A, B are included in aligned pairs which are separatedby ridges 3608. A first set of notches 3602A extend toward the ridges3608 from a first face 3610A of the shuttle 3600. The second set ofpaired notches 3602B extends toward the ridges 3608 from a second,opposing face 3610B of the shuttle 3600. Though the notches 3602A, B arealigned in the example embodiment, in other embodiments, notches 3602Acan be angularly offset from notches 3602B.

Referring now primarily to FIG. 33C, a cross section is shown depictingthe shuttle 3600 in an example interior valve cavity 3616. The notches3602A, B cooperate with one or more guide structures 3618 which extendfrom the interior wall 3620 of the interior valve cavity 3616 toward theshuttle 3600. The guide structures 3618 may be dimensioned so as to bereceived in the notches 3602A, B when a valve is assembled. The ridges3608 may also act as constraining features. The ridges 3608 may extendinto tracks 3622 within the interior valve cavity 3616 of a valve. Insome embodiments, the length of the tracks 3622 may serve to limittravel of the shuttle 3600 within the interior valve cavity 3616. As theshuttle 3600 is displaced, it may move, for example, until it isinhibited by the ridges 3608 abutting an end of their receiving tracks3622 in the interior valve cavity 3616.

As best shown in FIG. 33C, the portion of the overmolded coat 3604 overthe faces 3630A, B of the magnetic of metal body 3606 optionally isthicker than those covering the sides of the metal body 3606. In oneexample, the portion of the overmolded coat 3604 over the faces 3630A, Bis about 20-30% (e.g. 25%) the thickness of the metal body 3606. In aspecific example, the portion of the overmolded coat 3604 over the faces3630A, B is about 0.03″ thick.

Valve/Controller Manifold Modules

Valves such as binary valves, vari-valves, or any of the valvesdescribed herein may, in some embodiments, be supplied as modular thatcan be plugged into a manifold frame or base to provide pneumatic,hydraulic or electrical control of external devices, such as fluid flowcontrol devices, heaters, motors, or hydraulic or pneumatic devices. Anabstracted block diagram of such a valve module or valve manifold module2800 is shown in FIG. 34A. Each valve module 2800 may comprise one ormore valves 2802. Additionally, each valve module 2800 may includeelectronic components necessary to operate the valves 2802 included inthe valve module 2800. These can include an electronic controllerequipped to perform a number of programmed commands to the valves toallow the valve module 2800 to actuate or control an external device inat least a partially autonomous manner. A valve module 2800 may thus bean assembly of one or more valves 2802 connected to one or more on-boardPCBs (printed circuit or electronic control boards) populated withelectronic components 2808 suitable for operating the valvesautonomously or semi-autonomously with respect to a main or centralcontroller. This may help to offload some of the computing resourcesnecessary to run the valves 2802 from a main processor of a device. Themain processor may then only need to send a valve module 2800 higherlevel commands. These high level commands may include, for example,start commands, stop commands, pause/resume commands, commands toperform a measurement, commands to reverse liquid flow in an associatedflow control device, commands to properly sequence the operation ofon-board valves, commands to coordinate valve actions among a localgroup of modules, and commands to perform template functionspre-programmed on the PCB 2808. Once a higher level control program hasbeen received, the PCB 2808 may command a valve module 2800 perform avalve function (e.g., opening or closing a port in a prescribed sequenceor at a prescribed rate) in an autonomous manner without further inputfrom an external controller. Alternatively, the PCB may be programmed tooperate a valve module 2800 to perform a valve function in an entirelyautonomous manner without any input from an external controller.

In embodiments in which a valve manifold module 2800 includes aplurality of valve assemblies 2802, the PCB 2808 may be configured suchthat all of the valves 2802 in the module 2800 may be operated using acommon power source or bus. Additionally, in embodiments in which amodule 2800 includes multiple valve assemblies 2802, each of the valveassemblies 2802 may be mounted on a modular manifold base 2804 whichincludes or is connected to manifold fluidic (hydraulic or pneumatic)flow paths (fluid buses) for those valves 2802. An integrated manifoldassembly comprising a plurality of concatenated valve manifold modules2800 can thus be assembled (attached or connected together, for exampleby fasteners), and configured for control or operation of an externaldevice, such as a liquid flow control device (e.g. pump and valve devicefor transfer of a liquid). A modular valve/manifold assembly constructedin this manner can permit maintenance, repair or replacement ofindividual valve modules 2800 by plugging in or unplugging the valvemodule 2800 from the manifold. Also, within each valve module 2800 are abank of valve assemblies 2802 whose ports and electrical connections (aswell as housing dimensions) can be sufficiently identical to beinterchangeable among the designated receptacles in the module 2800. Aparticular valve manifold module 2800 can also be readily re-configuredfor operation of an external device having different features orfunctions (e.g., a different array of fluid flow control pumps andvalves, or a system with additional electronic, electrical, hydraulic orpneumatic functions).

Each PCB 2808 may include, for example, a pressure sensor which isconfigured to read the pressure of a fluid volume in the module. In someembodiments, the pressure sensors may read the pressure from wells inthe module manifold or block 2804 which fluidically communicate with thefluid pathways in the module block 2804. O-rings, gasketing, or anothersuitable seal may be included to provide a seal between the volume ofthe wells in the module block 2804 and the ambient environment. In someembodiments, one of more o-rings or gaskets may be compressed to createthe seal as the PCB 2808 is coupled to a module block 2804. In otherembodiments, the pressure sensors of the PCB 2808 may communicate withthe interior valve cavities of respective valves 2802 via any suitablefluid path. In the representational embodiment shown, the PCB 2808pressure sensors may for example be in fluid communication with theinterior valve cavities directly through a fluid path in each of therespective valves 2802. Alternatively, the PCB 2808 pressure sensors maybe in communication with the flow paths leading from the valve 2802outlets via a flow path through the end blocks 2806 on the ends of themodule 2800. Other arrangements may also be used.

Other sensors may also be included on the PCB 2808. Such sensors mayinclude current sensors. These current sensors may be configured tosense the current running through the electromagnetic coils of a valve2802 for example. Data provided by these current sensors may allow for adetermination to be made about whether or not a valve 2802 isfunctioning properly. The PCB 2808 may also be equipped to receiveelectronic signals from remote sensors, and to convert these signals todigital form using any suitable A/D converter mounted to the PCB. Suchsignals may be derived from remote pressure sensors, conductivitysensors, temperature sensors, air-in-line sensors, fluid level sensors,flow sensors, as well as other types of sensors depending on theapplication to which the application to which the valve/controllermodule is directed.

Additionally, a processor or processing components may be included onthe PCB 2808 and may allow a valve module 2800 to autonomously carry outor execute various valve-related applications. Thus a module 2800 mayrequire little or no direction from an external processor included inthe device in which the module 2800 is installed. The processor orprocessing components of the PCB 2808 may make use of and analyze datacollected from other components (e.g. pressure sensors) of the PCB 2808to meet the needs of a particular application.

There may be different modules 2800 for different valve applicationsthat are populated with different electronic components suitable for aparticular application. Additionally or alternatively, modules 2800 maybe programmed in a variety of different ways depending on intendedapplication. Some individual modules 2800 may be programmed such thatthey may perform a multiplicity of tasks. In some specific embodiments,the valve(s) 2802, the PCB 2808, and other components of the valvemodule 2800 may be overmolded together such that all of the componentsof the module 2800 are physically attached to one another and form asingle unit. In some applications, a valve/control module may bepermanently programmed to perform basic functions (e.g. coordinating theopening and closing of inlet and outlet valves while driving a pump,regulating the flow or pumping rate of the pump, detecting aberrant flowconditions, etc.), but may be automatically assigned more specific ordetailed tasks upon connection of the valve/control module to aparticular location on a communications control bus, such as acontroller area network (‘CAN’) bus.

Referring now also to the representational embodiment shown in FIG. 34B,each module 2800 may be configured such that it may be connectable toanother module 2800. This would allow a user to easily assembly amanifold 2850 which will suit a particular desired application. Tofacilitate such interaction, the valve modules 2800 may be arranged suchthat fluid pathways of each module 2800 may be connectable or coupleableto fluid pathways of another module 2800. End blocks 2806 may be placedon the ends of the manifold 2850 to allow an assembled manifold 2850 tointerface with other components such as a pressure reservoir or bus of adevice, and electronic communication bus of a device, and/or a power busof a device. An o-ring, gasket, or seal may be provided to ensureintegrity of the fluid paths within the manifold 2850.

When connected together, the electronic components of each connectedmodule 2800 may be placed into communication with one another. Thisallows for a number of connected modules 2800 to utilize power from asingle source (e.g. a device power bus). Communication also allows forsharing of valve state/pressure data between valves 2802 and facilitatesmodule to module synchronization. Additionally, this may allow for somemodules 2800 to be made with fewer or less complex electronic componentsmaking it more economical to build up a manifold 2850 out of a number ofvalve modules 2800. Module-to-module and system or main controller tomodule communication may be accomplished with any suitable communicationscheme, including, in some specific embodiments, a CAN-bus. It may bedesirable to utilize a CAN-bus communication scheme as it is low powerand is of relatively low complexity. Each module 2800 may include aterminating resistor which can be switched on and off to terminate themanifold 2850 if the module 2800 is at the end of the manifold 2850(and/or at the end of the CAN-bus communications chain).

A manifold 2850 of one or more valve modules 2800 may communicate withother components of a device wirelessly or via wired connection to adevice communication bus. In embodiments in which a manifold 2850 of oneor more valve module(s) 2800 is controlled remotely or wirelessly,inter-modular communication within the manifold 2850 optionally may alsobe wireless.

In some embodiments, each valve module 2800 may be configured asspecializable, but without a preset assigned functionality. That is, themodule 2800 may have the hardware capability to perform a full set ofvalve-related tasks or applications. Tasks may include, but are notlimited to, synchronization of inter-modular operations, functioning asmaster module for a multi-module manifold 2850, functioning as a pumpingmodule by supplying pressure to a pneumatically or hydraulically drivenfluid pump, functioning as a pneumatic or hydraulic valve controller bysupplying pressure to a pneumatic/hydraulic valve interface, etc. Insome specific implementations, tasks may include supplying pressure toan interface for a pumping cassette to effect pumping of fluid in thepumping cassette, supplying pressure to an interface for a pumpingcassette to actuate valves of the pumping cassette, supplying pressureto an interface for a pumping cassette to direct fluid flow through thepumping cassette, etc.

As modules 2800 are added onto a manifold 2850 carrying hydraulic orpneumatic supply lines, the modules 2800 may be specialized toparticular tasks or applications, which in an embodiment may beautomatically determined by the location of the module along aninterconnected chain of modules on a communications bus, such as aCAN-bus. Further specialization may also be imposed during operation bya system controller as required by particular applications. For example,a module 2800 specialized to act as a pumping module may be furtherprogrammed to pump at a specific pressure or flow rate.

By making each valve module 2800 specializable, manifolds 2850 assembledfrom the interconnection or concatenation of such modules 2800 would beeasily scalable. Such a module 2800 would allow for custom manifolds2850 to be easily built up and assembled with reduced developmenteffort. Additionally, modules 2800 would be easily swappable due totheir interchangeability, thus facilitating replacement of a module 2800within a pre-existing multi-module manifold 2850. In an embodiment, thespecific task assigned to a replaced module may be automaticallyassigned to the new module by (1) its location along the chain ofmodules on the communications bus, and/or (2) by a system controllerthat has been alerted to the presence of the new module (e.g. by aunique identifier) and its location on the communications bus or alongthe manifold assembly.

In some embodiments, modules 2800 may be self-enumerating and may beassigned a unique identifier after a module 2800 has been installed ontoa manifold 2850. A processor included on a PCB 2808 of a master modulemay take a census of the modules 2800 connected to one another in amanifold 2850. As mentioned above, any module 2800 may be assigned asthe master module. This census may be updated as additional modules 2800are added to the manifold 2850 or as modules 2800 are removed from themanifold 2850. The processor of the master module may also assign one ormore specialization(s) to each module 2800 forming the manifold 2850.The specialization assigned may depend on the physical position of amodule 2800 within the manifold 2800. In one example implementation,when the census of the manifold 2850 modules 2800 is taken, each module2800 may be assigned a unique identifier (e.g. module1, 2 . . . n). Thecensus may also determine the spatial arrangement of modules 2800. Forexample, a processor of the master module may determine, during thecensus, that module 2 is adjacent side A of module 1 and also adjacentside B of module 3. This spatial arrangement data aids in automaticassignment of module 2800 tasks. In some embodiments, spatialarrangement may be implied from identities of the modules 2800 afterthey are given their identifier. This may be an effect of the manner inwhich the modules are assigned identifiers. Alternatively, automaticenumeration of modules 2800 in a manifold 2850 need not be orchestratedby a master module, but may be accomplished by each module 2800determining its own identity in the manifold 2850 (described later inthe specification).

In some embodiments, new modules 2800 which are added to a manifold 2850either as replacements for old modules 2800 or to expand the size of themanifold 2850 may be automatically enumerated. As an example, if module2 has a fault and needs to be replaced with a new module 2800, theprocessor of the master module may detect when the new module 2800 hasbeen installed and automatically assign it as module 2. Alternatively,the new module 2800 may determine its own identity. The new module 2800may then assume the identity and task set of the original module 2,executing commands issued for module 2 and communicating with othermodules 2800 the same as the previous module 2.

Fault conditions may be communicated in an intermodular manner within amulti-module 2800 manifold 2850. This may allow a manifold 2850 to adaptto certain faults depending on the manifold 2850 configuration. Aprocessor of a master module may command that the manifold 2850 operatein a “limp home” mode in the event of particular fault conditions. Forexample, in the event that the manifold 2850 includes two pumpingmodules and one has a fault, the processor of the master module maydetermine the most efficient manner to continue pumping with the remainpumping module and command the modules 2800 of the manifold 2850 tooperate in that manner.

In a scenario in which a communications bus of a manifold 2800 has afault and is interrupted, but the power bus remains functional, modules2800 of the manifold 2850 may identify the fault and switch to operationin a fail safe mode. Fluid valves may, for example, be commanded toautomatically close. Any other desirable fail safe mode could also beimplemented. For example, a module 2800 could be programmed to continuepumping of fluid at a previously programmed or commanded flow rate. Inthis way, the failure of one module in the manifold assembly may resultin loss of communications to the downstream modules, but some of themodules may be allowed to operate in an autonomous manner until thesystem is wound down in an orderly manner. For example, a blood pumpmodule could be allowed to continue to operate for a designated periodof time if a dialysate pump module were to fail in a hemodialysissystem.

In some embodiments, modules 2800 may also be able to detect and reactedto various conditions of interest. For example, in embodiments where atleast one of the modules 2800 of a manifold 2850 is a pumping module, aprocessor of a module 2800 may be able to detect flow condition relatedinformation. In the event that an abnormal flow condition is detected(e.g. a reduced or no flow condition), the module 2800 may arrange forand/or perform troubleshooting or may request that the processor of themaster module command troubleshooting be performed. This troubleshootingmay determine, for example, if an occlusion exists. The manifold 2850may then cease pumping and signal that an error condition exists if anocclusion is detected.

FIG. 34C depicts a representational example diagram of a number of valvemodules 2800 installed in a pneumatic system 2852. Each module 2800includes a controller 2854 which may be included on a PCB of a module2800 as described above. Each module 2800 also includes a pneumaticblock 2856. The pneumatic block 2856 may include various pneumaticcomponents of a module 2800 such as one or more valves 2802 (see, forexample, FIG. 34A), a module block 2804 (see, for example, FIG. 34A)including fluid flow paths, and an end block 2806 (see, for example,FIG. 34A) if the module 2800 is at the end of a multi-module manifold.

Each module 2800 may connect to various buses of a device. As shown inthe example in FIG. 34C, a data/communications bus 2864 and power bus2866 are depicted. The data/communications bus 2864 may allow for dataor commands to be communicated from module 2800 to module 2800 within amulti-module manifold. This allows for synchronization and coordinationof module 2800 activities in a multi-module manifold. Additionally,commands and data may be conveyed to or from the manifold to an externalboard or processor via the data/communications bus 2864. The power bus2866 may supply power to the various modules 2800 in a manifold. Thispower may pass to the manifold via the power bus 2866 from a sourceexternal of the manifold. The data/communication bus 2864 and the powerbus 2866 may interface with a connector on a PCB 2808 (see, for example,FIG. 28A) of a module 2800.

A first pneumatic bus 2868, second pneumatic bus 2870, and thirdpneumatic bus 2872 are also shown. The first, second, and thirdpneumatic buses 2868, 2870, 2872 may each be connected to a pressurereservoir which is at a different pressure. Pneumatic buses 2868, 2870,2872 may interface with a connector on an end block 2806 (see, forexample FIG. 28A) of a multi-module manifold. Alternatively, pneumaticbuses 2868, 2870, 2872 may interface with a connector anywhere on apneumatic block 2856 of a module 2800. This module 2800 to busconnection may be accomplished in a plug and play fashion. Once a module2800 is connected to the appropriate buses, an identity for the module2800 may be determined and the module 2800 will be ready for operation.

As represented by the buses of the FIG. 34C running through each module2800 and on to the next, each bus may be conveyed through the modules2800 of a multi-module manifold. Electrical power and data communicationmay be conveyed through a module to module connector on a PCB 2808 (see,for example, FIG. 34A) of each module 2800. Pneumatic buses 2868, 2870,2872 may be conveyed through bus flow paths in the pneumatic block 2856which align with bus flow paths on the pneumatic block 2856 of anadjacent module 2800. Alternatively, each module 2800 in a manifold maybe individually connected to each bus. In certain embodiments, somepneumatic buses 2868, 2870, 2872 may only be in fluid communication withselected modules 2800 of a manifold. Some modules 2800 may haveoccludable ports to the pneumatic block, or may be constructed with alimited array of ports.

As shown, the controller 2854 of each module 2800 may issue valvecommands 2858 to control the valve(s) 2802 (see, for example, FIG. 34A)of that module 2800. The controller 2854 may also receive pressure data2860 from one or more pressure sensor(s) 2862 in a module 2800 whichsense the pressure of flow paths within the pneumatic block 2856. Thepressure data 2860 may be used by the controller 2854 to inform controlof the valve(s) 2802. In the example diagram, each module 2800 is shownas a pumping module which the controller 2858 may control to cause fluidto pumped by the pneumatic system 2852.

A first variable volume 2882 and a second variable volume 2884 areincluded for each module 2800 in the example pneumatic system 2852. Achange in volume of the first variable volume 2882 may in turn cause achange in volume of the second variable volume 2884. An increase involume of the first variable volume 2882 may cause a correspondingdecrease in volume of the second variable volume 2884. A decrease involume of the first variable volume 2882 may cause an increase in volumeof the second variable volume 2884. Two pneumatically driveninlet/outlet valves 2892 for the second variable volume 2884 areincluded and may be actuated to allow for the variable volumes 2882,2884 to change in volume.

As shown, the first variable volume 2882 and two inlet/outlet valves2892 are connected to the outputs of their respective modules 2800. Thevalves 2802 (see, for example, FIG. 34A) of each module 2800 may beactuated to increase or decrease the volume of the first variable volume2882. When the volume of the first variable volume 2882 is decreased,one inlet/outlet valve 2802 is open, and the other inlet/outlet valve2892 is closed, fluid will be drawn into the second variable volume2884. When the volume of the first variable volume 2882 is increased,one inlet/outlet valve 2892 is closed, and the inlet/outlet valve 2892is open, fluid will be forced out of the second variable volume 2884. Aswould be appreciated by one skilled in the art, pumping of fluid ineither direction may be accomplished by appropriate actuation of theinlet/outlet valves 2892.

The first and second variable volumes 2882, 2894 may be configured inany suitable arrangement which would allow a change in volume in one tobe tied to a change in volume of the other. For example, the firstvariable volume 2882 may surround or be surrounded by the secondvariable volume 2884. The first variable volume 2882 may be separatedfrom the second variable volume 2884 by a displaceable intermediarystructure which acts on the second variable volume 2884 as the firstvariable volume 2882 increases or decreases in volume. The intermediarystructure may be any suitable structure such as a piston, arm or lever,etc. The first and second variable volume 2882, 2884 may also beseparated from one another by a displaceable wall 2888 such as adiaphragm or a membrane made of a flexible material.

In some embodiments, there may be greater number of variable volumes. Insuch embodiments, a change in volume of the first variable volume 2882may cause a change in volume of a plurality of other variable volumes.Likewise, change in volume of a plurality of variable volumes may causea change in volume of one or more additional variable volumes.

In the representational diagram depicted in FIG. 34C, the first variablevolume 2882 is defined by a fixed wall 2886 and a displaceable wall2888. The second variable volume 2884 is adjacent the first variablevolume 2882 and is defined by a second fixed wall 2889 and thedisplaceable wall 2888. As the volume of the first variable volume 2882increases, the displaceable wall 2888 is pushed toward the second fixedwall 2889. As the volume of the first variable volume 2882 decreases,the displaceable wall 2888 is pulled toward the first fixed wall 2886.

Another example pneumatic system 2852 is depicted in therepresentational diagram in FIG. 34D. The example pneumatic system 2852is similar to that depicted in FIG. 34C, however, a fourth pneumatic bus2873 is included. The fourth pneumatic bus 2873 may be connected to avent reservoir such as the atmosphere. The other three pneumatic buses2868, 2870, 2872 may be connected to pressure reservoirs. For examplethe first pneumatic bus 2868 may be connected to a negative pressurereservoir, the second pneumatic bus 2870 may be connected to a lowpositive pressure reservoir, and the third pneumatic bus 2872 may beconnected to a high positive pressure reservoir. Including a vent oratmospheric bus may be desirable as it may help to minimize the amountof pumping necessary to maintain reservoirs for the other buses 2868,2870, 2872. For example, when switching a volume from positive pressureto a negative pressure or vice versa, it may be desirable to vent thevolume to ambient pressure. This would avoid excessive depletion of thepressure reservoirs as it lowers the pressure difference between thevolume and the reservoir. It should be appreciated that any other numberof pneumatic buses may be included in various embodiments. Additionally,the number of electrical buses may vary as well.

Another example pneumatic system 2852 is depicted in therepresentational diagram in FIG. 34E. The example pneumatic system 2852is similar to that depicted in FIG. 34C, however, module to moduleconnectors 2865 are depicted on the data/communication bus 2864 in FIG.34E. The module to module connectors 2865 may consist of cooperatingpieces of hardware on each module 2800 which serve to create anelectrical communication pathway from module 2800 to module 2800 in amulti-module manifold.

As shown the module-to-module connectors 2865 may allow for theconnection established to be interruptible in response to commands fromthe controller 2854 of each module 2800. This is signified by a switchin each of the module-to-module connectors 2865. This may beparticularly desirable when a manifold is being auto-enumerated or whena new module 2800 is being installed in the manifold as a replacement.In a specific embodiment, a module 2800 may interrupt communicationscoming from one side of the manifold. That is, the module may interruptcommunications in a first direction while leaving communications in asecond direction enabled. In the example diagram shown, the third module2800 from the left has interrupted communications to and from modules2800 to its right or downstream side. This may be a defaultconfiguration of each module 2800 upon installation into a manifold.When communication has been interrupted, a terminating resistor on themodule 2800 may also be switched in.

Each message sent on the data/communication bus 2864 may be uniquelymarked according to the module 2800 from which it originated. Afterinterrupting communications, a module 2800 may then poll modules 2800 onthe portion of the manifold that the module 2800 is still incommunication with. These modules 2800 may respond to the new module2800 and the new module 2800 will determine its identity or functionbased upon the responses received. For example, if the module 2800 onlyreceives responses from modules 1 and 2, the new module 2800 willdetermine that it must be module 3. Messages addressed with the uniquemarker for module 3 may then be received and acted upon by the newmodule 2800. Communication with the rest of the manifold may bereestablished and the next module 2800 may repeat the process todetermine its identity or function, and so on. When communications arereestablished, a terminal resistor included on newly enumerated module2800 may also be switched off.

Alternatively, after a module 2800 interrupts communications to one sideof the manifold, the module 2800 may wait for a period of time andreceive messages sent across the data/communication bus 2864. The module2800 may then determine its identity or function based upon the uniquemarkers of the messages sent across the data/communication bus 2864. Ifthe new module 2800 only receives messages from module 1 and 2, the newmodule 2800 may then determine that it must be module 3. As above,communication with the rest of the manifold may be reestablished andthis process may repeat until each module 2800 in a manifold hasauto-enumerated. A terminal resistor which may be switched in and outmay be included on each module 2800 and operate as described above.

As would be appreciated by one skilled in the art, any other schemeinvolving interruption of the communication bus to facilitateauto-enumeration of modules 2800 in a multi-module manifold may also beused. Also as mentioned above, this process need not be performed byeach individual module 2800 in the manifold. In some embodiments, theprocess may be conducted or coordinated by a master controller in themanifold.

FIG. 34F depicts another example pneumatic system 2852 similar to thatdepicted in FIG. 34C. As shown, the example pneumatic (or hydraulic)system 2852 in FIG. 34F, includes a number of modules 2800 which arearranged to perform a plurality of different valve related tasks. Itshould be appreciated that the tasks shown are only exemplary.

The third module 2800 from the left is arranged as a pumping modulesimilar to those shown in FIG. 34C. The two left-most modules 2800 arearranged to control a two chamber fluid pump 2896. The controllers 2854of the two left most modules 2800 may operate in tandem, coordinating orsynchronizing pumping operations between one another to optimize fluidthroughput or achieve substantially continuous pumping, for example. Thecontrollers 2854 may communicate over the data/communication bus 2864 tosynchronize with one another. Each controller 2854 may also sendcommands 2858 to their respective pneumatic blocks 2856 in order toeffect pumping of fluid in each module's 2800 respective chamber of thefluid pump. In one synchronization scheme, the controller 2854 of onemodule 2800 may be synchronized such that it commands filling of itsassociated chamber while the other commands delivery of its associatedchamber. Thus fluid may be pumped to one of a first or second reservoir2890, 2895 in a substantially continuous fashion from the otherreservoir. Modules 2800 may similarly coordinate to synchronizeoperations between a greater number of fluid pumping chambers as well.For example, a three chamber fluid pump may be controlled by threemodules 2800 which communicate over a data/communication bus 2864 tosynchronize pumping.

The rightmost module 2800 is configured as a pneumatic (or, in othersystems, hydraulic) valve module and controls only valves in the examplediagram shown in FIG. 34G. As shown, the outputs of the module 2800 areconnected to a number of fluid valves 2897 which control fluidcommunication to various fluid pathways 2898 in the pneumatic system.The number of fluid valves 2897 may be greater or less than the numbershown. Depending on the number of valves included in a module 2800, theamount of fluid valves 2897 the module is capable of controllingindependently will differ.

FIG. 34G depicts another example pneumatic system 2852 similar to thatdepicted in FIG. 34C. As shown, the example pneumatic system 2852 inFIG. 34G, includes a number of modules 2800 which are arranged toperform a plurality of exemplary valve related tasks including fluidpumping and pneumatic fluid valve 2897 actuation. As in FIG. 34F, thefluid valves are shown controlling communication to various flow paths2898 in the pneumatic system 2852. Also as shown in FIG. 34F, the thirdmodule 2800 from the left is shown controlling a fluid pump.

The leftmost and second leftmost module 2800 are depicted ascooperatively controlling a single fluid pump. Having a plurality ofmodules 2800 cooperatively controlling a single fluid pump may allow formanifolds to be made smaller and may allow for manifolds to operate moreefficiently depending on the scenario. Additionally, such cooperativecontrol may allow for a greater range of pressures to be used whilepumping. For example, a first module 2800 may provide fluid at a firstnegative pressure and a second negative pressure while a second modulemay provide fluid at a first positive pressure and a second positivepressure. Another benefit of cooperative control is that it allows forcontrol of a fluid pump requiring a greater number of valves 2802 than asingle module includes.

As shown in the specific example, the leftmost module 2800 controls thestate of two inlet/outlet valves 2892 of the second variable volume 2884of fluid pump. The leftmost module 2800 also controls a pressure inputto the first variable volume 2882 of the fluid pump. The other module2800 controls another pressure input to the first variable volume 2882as well as another inlet/outlet valve 2892 of the second variable volume2884. To coordinate pumping operations for the fluid pump, the processor2854 of each cooperating module 2800 may synchronize valve activityrelated to the fluid pump over the data/communication bus 2864. Thisallows a manifold assembled from modules 2800 each including four valves2802 to run a fluid pump requiring five valves 2802.

While the above description relates to use of modules 2800 to controlvarious pneumatic components (e.g. pneumatically driven pumps and/orvalves), it should be recognized that such modules 2800 may be easilymodified to control a wide range of components or devices. A similararrangement may be used to control hydraulically actuated pumps and/orvalves, with the manifold valve module 2800 making a hydraulicconnection to one or more pressurized hydraulic lines in a system. Sucha connection may be made using, for example, quick-connect fittings toallow for ready replacement of manifold valve modules 2800 in need ofmaintenance or repair, or replacement with manifold valve modules 2800configured for different combinations of pumps or valves.

As illustrated in the representation diagram in FIG. 34H, a module 2800may include a PCB 2808 with a processor 2854 which is programmed to selfsufficiently command operation of one or more motors 2841. The PCB 2808may include electrical outputs to each winding of the motor 2841. Insome embodiments, the motor 2841 and PCB 2808 may be included as asingle package and the PCB 2808 may be overmolded onto a portion of themotor 2841. Similarly a module 2800 may be modified to self sufficientlycontrol operation of one or more pump 2842. The PCB 2808 of the module2800 may include electrical outputs which interface with the pump. Insome configurations, the pump 2842 and PCB 2808 may be included as asingle package and the PCB 2808 may be overmolded onto a portion of thepump 2842. A module 2800 may be programmed to control illumination ofone or more light emitters 2843 as well.

Modules 2800 may be configured such that the PCB 2808 includes acontroller 2854 which is programmed to control operation of one or moreelectromagnets 2844 based on a pre-defined program. The PCB 2808 mayinclude an electrical output which interface with the contacts of theelectromagnets 2844 to energize the electromagnets 2844 in any desiredfashion. Additionally, modules 2800 may be modified to self sufficientlycontrol operation of one or more heater elements 2845. In suchembodiments, a module 2800 may include a PCB 2808 with a controller 2854that is capable of switch current flow through the heater element 2845on and off in any desired manner. Again, this may be accomplished basedupon a pre-defined program or based on high level commands from anexternal main controller. For example, the main controller may commandthat the heater element 2845 warm a surface to a temperature set point.The module 2800 may then execute all of the necessary control functionsto get the surface to the commanded temperature set point using theheater element 2845 and feedback signals from a suitably locatedtemperature sensor. The on-board module controller 2854 may beconfigured to provide analog control of the heater element 2845, ordigital control through, for example, application ofpulse-width-modulated current to the heater element 2845. In someembodiments, a module 2800 may not directly mediate current flow throughthe module 2800 to the heater element 2845. Instead, the module 2800 maycontrol a relay making or breaking a connection between a current sourceand a heater element 2845. This may be desirable in scenarios in whichthe heater element 2845 is run at high voltages (e.g. mains voltage).Modules 2800 may control relays used in other applications as well. Suchrelays may comprise high speed digital devices, such as thyristors,TRIACS, or silicon controlled rectifiers.

A module 2800 may include a PCB 2808 with any of a variety of sensors2840 suited for particular applications. For example, modules 2800 maybe populated with current sensors, temperature sensors, pressuresensors, encoders, optical sensors, magnetic sensors, inertial sensors,or any other sensor as required by the module 2800 application.

As described above, modules 2800 used for control of other devices orcomponents can be configured to share power transmitted through a sharedpower bus 2866. Such modules are also able to coordinate or synchronizeoperation via a shared data/communication bus 2864. This coordinationmay be between similar or dissimilar devices or components. For example,such coordination may help to limit or manage peak power loads amongother benefits.

FIG. 35A depicts a specific example embodiment of a valve module 2900.As shown, the example embodiment includes four valve assemblies 2902. Inother embodiments, a valve module 2900 may include any suitable numberof valve assemblies. The valves 2902 may be any of a variety of types ofvalves including binary valves, variable valves, or bi-stable valvessuch as any of the embodiments described herein. The valves 2902 can bemounted on a manifold module base or block 2904 as shown. The moduleblock 2904 includes a number of fluid channels or flow paths whichinterface with the fluid inlets and outlets of each valve 2902. Themodule block 2904 may thus form a manifold for the valve assembly 2902.In embodiments comprising bi-stable valves such as those describedherein, one of the inlet ports for one or more valve assemblies in themodule 2900 can be blocked. This may allow the bi-stable valve toeffectively function as a two-way valve. Additionally, a module base orblock 2904 may include one or more fluid buses—flow paths which canconvey pressurized fluid (e.g. pneumatic or hydraulic) from apressurized fluid source line to a series of interconnected manifoldmodules. Any number of manifold modules can be concatenated or connectedin series, each having a fluid bus connecting a pressure line inlet porton one side of the module to a pressure line outlet port on another sideof the module. Modules can be connected together by standard fasteners,with inlet and outlet ports joined via gaskets or O-rings, for example.Thus in a pneumatic system, one or more pneumatic buses can be assembledin a manifold assembly from module 2800 to module 2800 in a multi-modulemanifold assembly.

Also shown in FIG. 35A are manifold module end blocks 2906. The endblocks 2906 may be attached to the ends of a manifold assembly assembledfrom a number of valve modules 2900. The end blocks 2906 may includeconnection ports 2907 connecting one or more pressure line inputs oroutputs to corresponding pressure line input or output ports of thevalved module(s) 2900 making up a manifold. For example, the connectionports 2907 may connect to pressurized fluidic components such aspneumatic lines or buses from one or more positive pressure sources orreservoirs, negative pressure reservoirs, a vented source or reservoir(e.g. atmosphere), or other reservoir. Any suitable connector fittingmay be incorporated into the connection ports 2907, including, forexample quick-connect fittings. If not all of the connection ports 2907of a module 2900 are to be used, the unused connection ports 2907 may beplugged, blocked, or otherwise sealed off. In the example embodimentshown, three connection ports 2907 are included. In other embodiments,the number of connection ports 2907 may differ. For example, someembodiments, may only include two connection ports 2907 (FIG. 35E). Themodule end blocks may function as a terminal block in a series or bankof connected modules, in which case the connection ports are closed orblocked. Alternatively, the terminal block connection ports may beconnected to one or more fluid lines leading to an end block forming aninput block of another bank of manifold modules in a larger manifoldassembly. In some embodiments, an assemblage of module banks may bestacked as shown in FIG. 35E, allowing input end blocks to beinterconnected to supply each bank of modules with one or morepressurized fluid lines. In this case, the connection ports of theterminal blocks of each bank of modules can be sealed closed or blocked.

An exemplary on-board controller board (PCB) 2908 is included in themodule depicted in FIG. 35A. As shown, the example PCB 2908 of the valvemodule 2900 includes capacitors 2910. FIG. The capacitors 2910 may beselected to have a capacitance sufficient to power the valves 2902 to aknown or desired state in the event that power to the valve module 2900is lost. If the electrical power and/or communications bus voltage of adevice sensed by the PCB 2908 of the valve module 2900 drops below apredetermined level, valve(s) 2902 may be transitioned to a preferred orpre-determined configuration (i.e. a valve state that closes a specifiedfluid port or opens a specified fluid port). This could, for example,represent a fail-safe configuration for the apparatus controlled by themodule (e.g. a fluid flow control device such as a pump and/or valves ina medical device). In the event that power from the device isunavailable, the capacitors 2910 of the valve module 2900 may be reliedupon to transition the valve(s) 2902 to the preferred defaultconfiguration.

A number of processing components are included on the PCB 2908 as well.These processing components may include, for example, FGPAs (fieldprogrammable gate arrays), microprocessor chips, etc., or a combinationthereof. Preferably, the processing components are capable of performingsignal processing of data provided at a relatively high sampling rate(e.g. pressure data from on-board pressure sensors 2918 connectable toports 2916 on the module block communicating with the valve cavities ofthe individual valve assemblies). The PCB controller can thus controlthe valve(s) 2902 or electrical outputs in the module 2900 moreaccurately or at a correspondingly high rate.

The PCB 2908 may include a number of connectors 2912. In the exampleembodiment, only two connectors 2912 are shown. In other embodimentsthere may be a greater or smaller number of connectors 2912 included ina valve module 2900. Referring now also to FIG. 35B, the connectors 2912allow a valved module controller 2908 to be connected to additionalneighboring or adjacent valved module controllers 2908 to interconnectvalved manifold modules 2900 into a manifold 2950 of any desired size orcomplexity. The connectors 2912 allow for a communications and/orelectrical power bus to be assembled in a bank of manifold modules,allowing for communication of power and/or data between various valvemodules 2900 comprising a manifold assembly 2950. Additionally, theconnectors 2912 may allow for electronic communication (power and/ordata) between valve modules 2900 in a manifold assembly 2950 and anexternal (e.g. main or system) controller (not shown) included in adevice in which the manifold assembly 2950 is installed.

Each module block 2904 may include one or more coupling features whichmay facilitate connecting modules 2900 together to form a bank ofmodules or manifold assembly 2950. In the example embodiment shown inFIG. 35A-B, the module blocks 2904 include a number of holes 2914through which a suitable fastener (not shown) may be placed to couplethe module blocks 2904 together. The fastener may be any suitablevariety of fastener. A suitable fastener may also be used to couple theend blocks 2906 of a manifold 2950 to the valve modules 2900 at the endsof the manifold 2950. As mentioned above, where various fluid pathwaysbetween the valves 2902, module blocks 2904, and/or end blocks 2906interface with one another, a sealing member such as an o-ring, gasket,or the like may be used to ensure leak-free connections. In a typicalassembly procedure, module bases or blocks are first mated side-to-side,aligning the pressure line input ports and pressure line output ports ofadjacent blocks. The blocks are fastened together, using gaskets orO-rings as appropriate to form a seal between the input and outputports. One or more valve assemblies may also be installed in eachmodule, either before or after the modules are concatenated. Valveassemblies are positioned over designated receiving stations on themanifold base or block, aligning the inlets of the valve assemblies withpressure ports communicating with the appropriate fluidic pressure busin the module block, and aligning the outlet of each valve assembly witha port on the module block that fluidly communicates with an outlet ofthe module block. A gasket (see, e.g. gasket 4602 in FIG. 40 , or gasket4184 in FIG. 28C) having appropriately located ports or holes may beinterposed between the face of the valve assembly and the matingreceiving face of the module block. In some embodiments, the gasket maynot have ports communicating with all fluidic pressure buses passingthrough the module block. Once the module blocks are interconnected andthe valve assemblies are installed, the controller board may be mountedon the module and valve assemblies. Alternatively, each controller boardcan be installed on a valved module block before the individual modulesare interconnected, resulting in externally uniform, programmable valvedmanifold modules that can be readily assembled together, forming anexpandable manifold assembly having standardized fluidic and electronicinputs, outputs, valve mating dimensions and similar controllers thatcan be programmed for various tasks. In installing the electroniccontrol board, pressure sensors mounted on the board are aligned withpressure sensing ports or wells on the module block that communicatewith the cavity of the valve assembly. If electromagnetic coils aremounted on the valve assembly, electrodes on the electronic controlboard are also aligned with corresponding receptacles or electrodesconnected to the coils. The valve assemblies may be securely fastened tothe module block, and the control board may be securely fastened to themodule block using standard methods, such as screws, for example. In theexamples shown, a typical module has four valve receiving stations ontowhich a controller board positions four pressure sensors—one for eachinstalled valve. Modules can be constructed to have fewer receivingstations without necessarily compromising the expandability of themanifold module system. A greater number of valve assembly receivingstations may necessitate changes in the module block and control boardto accommodate the additional valve assemblies, and may also requiremodifications to any rack or mounting frame used to assemble banks ofmanifold modules.

In many applications, a four-valve manifold module can functionindependently to operate a single pump. For example, a liquid inletvalve and outlet valve of the pump can each be assigned and connected tothe output of a separate manifold valve, which can toggle between apositive fluidic pressure bus and negative fluidic pressure bus in themodule to either close or open the inlet/outlet pump valve. A thirdmanifold valve can be arranged to toggle on or off a connection of thepositive pressure bus to the pump control chamber to perform a pumpdeliver stroke, and a fourth manifold valve can be arranged to toggle onor off a connection of the negative pressure bus to the pump controlchamber to perform a pump fill stroke. The pump control manifold valvescan be converted to two-way valves (on/off) by installing them on themodule block using a modified gasket having no port to the positivepressure bus if used as a fill control valve, or having no port to thenegative pressure bus if used as a deliver control valve. The on-boardcontroller can be programmed to independently operate the liquidpump/valve unit by coordinating the inlet and outlet pump valves topermit filling the pump chamber with liquid and then expelling theliquid from the pump chamber in the direction assigned by the program.The controller can also receive pressure data from the pump controlchamber to determine rate of fluid volume movement and end-of-strokeconditions. It can also be programmed to vary the rate or amount ofpressure delivered to the pump control chamber. The on-board controllercan also receive command sets locally from other manifold modulecontrollers, or from an external main or system controller.

FIG. 35C depicts a partially exploded view of the example valve module2900 depicted in FIGS. 35A-B. As shown, the PCB 2908 includes a numberof pressure sensors 2918. In the example embodiment, the number ofpressure sensors 2918 is equal to the number of valves 2902 included inthe valve module 2900. In other embodiments, the number of pressuresensors 2918 may vary. When the PCB 2908 is attached to the module baseor block 2904, the pressure sensors 2918 are disposed in respectivesensing wells or ports 2916 included as a part of the module base orblock 2904. As mentioned above, o-rings, gaskets, or any other suitablesealing member may be used to seal the sensing wells 2916 from theambient environment.

Each of the sensing wells 2916 is in fluid communication with theinterior valve cavity of one of the valves 2902. The sensing wells 2916may thus allow for the pressure sensors 2918 on the on-board PCB 2908 tosense the pressure of the interior cavity of the valves 2902. Thecollected pressure data may be supplied to the processing components orcontroller included on the PCB 2908 for signal processing. The valvecavity pressure may be measured periodically or monitored in real time,acquired and stored by the on-board controller, and used by the on-boardcontroller to control the valves 2902 of a valve module 2900 to executeparticular tasks, such as selected delivery of one or anotherpressurized fluid (e.g. air) to a controlled device, such as a pumpand/or valve in a liquid flow control apparatus. If the valve controls asingle pressure line, or if it is configured to be able tosimultaneously block more than one pressure line, then the on-boardcontroller can receive pressure data that represents the pressurepresent in the controlled device (the valve cavity being in fluidcommunication with a control chamber, for example, of a controlledmembrane pump). Using the specific example of a valve module 2900 whichis assigned the task set of a pumping module, the pressure data may beused to determine, among other things, an amount of liquid transferredand a flow rate of the liquid being transferred in the liquid flowcontrol apparatus. Pressure data may also be used, for example, duringtroubleshooting.

As shown in FIG. 35B, a series of interconnected (or bank) of manifoldmodules 2900 causes the on-board controllers to be interconnected 2912on a communications and/or power bus. This allows each manifold module2900 to be assigned a specific task or set of tasks by an external mainor system controller, or additionally or alternatively allows a bank ofon-board controllers to establish a ‘master-slave’ or primary-secondaryhierarchical relationship. Through the transmission of identifying datato or from each module controller, any or all of the module controllerscan detect the presence of and/or function of any other module in thebank or in an entire manifold assembly 2950. If a controlled device hasa plurality of functions or plurality of pump/valve combinations, aprimary module controller can be assigned, which can then coordinate orsynchronize the functions of a group of secondary modules with respectto the controlled device. In some cases, a linked control group ofmodules may only be a subset of a plurality of manifold modules in abank or manifold assembly.

FIG. 35D depicts a top, back, left perspective view of the examplemodule 2900 shown in FIG. 35A. As shown, the example module includes anumber of output ports 2955. These output ports 2955 may allow fortubing to be connected to the module 2900. This tubing may then run to adestination for the module's 2900 outputs. In various embodiments, thedestination may, for example, be a fluid pump, pneumatic valve, fluidreservoir, etc. Any suitable connector fitting may be included as partof the output ports 2955. If not all output ports 2955 of a module 2900are to be used, the unused output ports 2955 may be plugged, blocked, orotherwise sealed off.

FIG. 35E shows a perspective view of a number of modules 2900 that havebeen incorporated together to form a manifold assembly 2950. Banks ofmodules 2900 are placed on a number of individual module racks or frames2970. The module racks or frames 2970 each hold a group or bank ofmodules 2900. In the example shown, each group includes four modules2900 though alternative racks or frames 2970 may hold any desired numberof modules 2900. Each rack 2970 may include mating or coupling featuresthat allow it to be easily stacked upon another rack 2970, forming arack or frame assembly. For example, a first side of each rack 2970 mayinclude a pin or projection. A second side of each rack 2970 oppositethe first side may include a receiving structure which can retain theprojection from the first side of an adjacent rack 2970 connecting thetwo racks 2970 together. A cap 2972 optionally may be placed on the topor terminal rack 2970.

Each rack may include tracks 2974 or a frame in which modules 2900 maybe retained. These tracks 2974 may be designed such that modules 2900may be easily slid in and out of a rack 2970 during assembly of anintegrated manifold 2950. In some embodiments, the tracks 2974 ensurethat modules 2900 may only be installed in one orientation to ensurethat all modules 2900 face the same direction. The tracks 2974 may alsoaid in alignment of connectors 2912 as a manifold 2950 is assembled. Inan embodiment, the end blocks 2906 shown in FIGS. 35A-E can be modifiedto form at least part of the supporting structure of a rack or frame2970. Any individual track 2974 can accommodate any number of manifoldmodules in a bank, each module having a slot in the rack or frame intowhich it can be placed. Individual modules can be concatenated in a bankby mating the pressure line inlet port of one module with pressure lineoutlet port of an adjacent module to form the fluidic pressure bus, andby installing the module control boards so that they interconnect viaadjacent electronic communications connectors to form thecommunications/power bus. Thus a manifold assembly 2950 formed from astack of modules can be readily modified to accommodate any number orcombination of manifold modules 2900, depending on the complexity orneeds of the device being fluidically or electrically controlled by themanifold assembly.

A communications/power bus extension line 2913 may extend betweenmodules 2900 on one rack 2970 to modules on the next rack 2970. This mayallow for the same communication/power bus to be used for all of themodules 2900 in the manifold assembly 2950. In some aspects, thecommunications/power bus extension line 2913 may be integrated in eachrack 2970. As modules 2900 are installed in the rack 2970 they mayconnect to a communications/power bus which is housed within the rack2970 structure. As racks 2970 are stacked upon one another, the integralcommunications/power bus lines for each rack 2970 may be placed intocommunication or connected with one another. This connection may beautomatically established when the racks 2970 are properly attached toone another. This may help to allow for rack 2970 to rack 2970communication to be easily established when assembling a manifold 2950.

Similarly, pneumatic (or in other systems, hydraulic) communicationbetween modules 2900 on different racks 2970 may be established withpneumatic distribution lines housed or integrated within each rack 2970(e.g. via modified end blocks 2906). The modules 2900 may connect anddraw from these lines when installed in each rack 2970. Additionally, asracks 2970 are stacked, fluidic (e.g. pneumatic) communication from rack2970 to rack 2970 may be automatically established. The connections maybe made, for example, by press-fit plug/receptacle pairs having suitableleak-proof contact surfaces (such as, e.g., elastomeric gaskets orO-rings). Alternatively, pneumatic lines may run individually to eachrack 2970 of a manifold. This may be desirable in some embodiments, asit may allow for different groups of modules 2900 of a manifold 2950 todraw from a variety of different pressure sources.

Referring now to FIG. 35F a representational diagram showing a number ofmodules 2900 arranged in a manner similar to that shown in FIG. 35E. Themodules 2900 are split into a number of groups 2980A-D. Each module 2900is connected by connectors 2912 and each group is connected by acommunications/power bus extension line 2913 so that all modules may beconnected on the same communications/power bus. In the exampleembodiment in FIG. 35F, the groups of modules 2900 of the manifold 2950draw from different pressure sources 2982A-D. Groups 2980A and 2980Bdraw from pressure sources 2982D and 2982C. Group 2980C draws frompressure sources 2982B and 2982C. Group 2980D draws from pressuresources 2982A and 2982B. Such an arrangement may, for example, allow formodule manifold blocks 2904 (FIG. 29C) to be simplified as the number offluid pathways required in each manifold block 2904 (FIG. 29C) can bereduced. One group 2980A-D may, for example, be connected to a firstpositive pressure line. Modules 2900 within that group 2980A-D may beassigned as pump chamber controlling modules 2900. Another group 2980A-Dmay be connected to a second, higher positive pressure line. Modules2900 within that group 2980A-D may be assigned as fluid valvecontrolling modules 2900.

An example schematic of a pneumatic pumping system 3000 including amanifold 3050 consisting of a single valve module 3060 is shown in FIG.36 . In the specific example shown, the valved module 3060 is configuredas a pumping module and is similar to the valved module 2900 depicted inFIG. 35A. The example module 3060 shown in FIG. 36 includes four valves3002A, 3002B. The valves 3002A, 3002B may be any suitable type ofvalves, such as any of the bi-stable valves described herein, binaryvalves, or even variable aperture valves. Each of the valves 3002A,3002B (or more specifically valve cavities or valve outlet ports) can beplaced in fluid communication with a pressure sensor 3018. The valves3002A, 3002B of the module 3060 are commanded by a controller (which maybe an on-board controller, or optionally an external controller), andthe pressure sensors 3018 are configured to communicate with thecontroller. The controller may command the valves 3002A, 3002B toparticular valve states based upon data collected by the pressuresensors 3018.

A first variable volume 3082 separated from a second variable volume3084 by a movable barrier 3088 are included in the example pneumaticsystem 3000. A change in volume of the first variable volume 3082correspondingly causes a change in volume of the second variable volume3084. An increase in volume of the first variable volume 3082 causes acorresponding decrease in volume of the second variable volume 3084. Adecrease in volume of the first variable volume 3082 causes an increasein volume of the second variable volume 3084. The first variable volume3082 may be referred to herein as a control chamber. The second variablevolume 3084 may be referred to herein as a pumping chamber.

The first and second variable volumes 3082, 3094 may be configured inany suitable arrangement which would allow a change in volume in one tobe tied to a change in volume of the other. In the example schematicdepicted in FIG. 36 , the first variable volume 3082 is defined by afixed wall 3086 and a displaceable barrier 3088. The second variablevolume 3084 is adjacent the first variable volume 3082 and is defined bya second fixed wall 3089 and the displaceable barrier 3088. As thevolume of the first variable volume 3082 increases, the displaceablebarrier 3088 is pushed toward the second fixed wall 3089. As the volumeof the first variable volume 3082 decreases, the displaceable barrier3088 is pulled toward the first fixed wall 3086. The displaceablebarrier 3088 may be a membrane or diaphragm, which in some embodimentsmay be constructed of one or more pieces of flexible or elasticsheeting.

As shown, the pneumatic system 3000 includes a first positive pressureinput 3075, a second positive pressure input 3077 (which may be at ahigher positive pressure than the first positive pressure source 3075),and a negative pressure input 3080. The positive and negative pressureinputs 3075, 3077, 3080 are connected to the manifold assembly 3050. Byactuating the valves 3002B in an appropriate manner, positive ornegative pressure may be supplied to a first variable volume 3082 of anexternal fluid flow control device. Additionally, valve 3092 and valve3094 communicating with the second variable volume 3084 may also becontrolled by actuating the respective valves 3002A.

When the first variable volume 3082 is connected to positive pressureand raised to a positive pressure, the first variable volume 3082increases, displacing liquid present in the second variable volume 3084.When the first variable volume 3082 is connected to a negative pressureand lowered to a negative pressure, the first variable volume 3082decreases in volume, allowing the second variable volume 3084 to draw inliquid via a liquid flowpath. The first variable volume 3082 may be incommunication with at least one pressure sensor 3018 so that thepressure of the first variable volume 3082 can be monitored. Optionally,the inlet valve 3092 and outlet valve 3094 connected to the secondvariable volume 3084 may also be in communication with one or morepressure sensors 3018 so that their pressures may also be monitored.

The change in volume of the second variable volume 3084 in response tothe change in volume of the first variable volume 3082 may be used topump fluid out of the second variable volume 3084 in a controlledmanner. As shown, the second variable volume 3084 is connected to afirst fluid reservoir 3090. Depending on the configuration of the liquidflow paths, the second variable volume 3084 may be connected to aplurality of fluid reservoirs in some examples. For exemplary purposes,in a medical device, the first fluid reservoir 3090 may contain a liquidsuch as dialysate. It should be appreciated that the first fluidreservoir 3090 may contain any type of liquid or fluid. By opening valve3092 and connecting the first variable volume 3082 to a negativepressure, fluid may be drawn into the second variable volume 3084 fromthe first fluid reservoir 3090. The second variable volume 3084 is alsoconnected to a second fluid reservoir 3095. By closing valve 3092,opening valve 3094 and connecting the first variable volume 3082 topositive pressure, fluid may be pumped out of the second variable volume3084 to the second fluid reservoir 3095. By opening and closing valves3092 and 3094 in the opposite manner, fluid may be pumped in theopposite direction.

The magnitude of the pressure supplied to the first variable volume 3082may have an effect on the rate of fluid transfer into or out of thesecond variable volume 3084. Increasing the magnitude of the pressure inthe first variable volume 3082 may cause the rate of fluid transfer toincrease.

As the pressure in the first variable volume 3082 controls how fluidwill be transferred through the pumping system 3000, the first variablevolume 3082 can be referred to herein as a control chamber. Since thefluid transferred is transferred into or out of the second variablevolume 3084, the second variable volume 3084 may be referred to hereinas a pumping chamber.

A fill stroke of the pumping chamber occurs when negative pressure issupplied to the control chamber 3082 such that the volume of the pumpingchamber 3084 increases from a starting volume (e.g. substantially itsminimum volume) to a designated volume, or alternatively tosubstantially its maximum volume. A delivery stroke of the pumpingchamber occurs when positive pressure is supplied to the control chamber3082 such that the volume of the pumping chamber 3084 decreases from astarting volume (e.g. substantially its maximum volume) to a designatedvolume, or alternatively to substantially its minimum volume. The term“stroke” is used to generically refer to supplying pressure to thecontrol chamber 3082 to cause fluid transfer to or from the pumpingchamber 3084. Stroke displacement refers to the amount of volume changethat occurs in one of the variable volumes at any given point in astroke. The end-of-stroke is meant to signify when a pumping stroke hascompleted and the pumping chamber 3084 is at substantially its maximumvolume or minimum volume. In some applications, the pumping chamber maybe included in a fluid handling cassette and the control chamber may beincluded as part of a cassette interface of a base unit to which amanifold assembly 3050 or manifold module of the manifold assembly isarranged to supply pressure.

FIG. 37 depicts a schematic diagram of a module 4200 which is arrangedto pump liquid from a pumping chamber 4202 and make a measurement of thevolume of liquid pumped. The example module 4200 shown in FIG. 37includes seven valves 4204A, 4204B, 4204C. The valves 4204A, 4204B,4204C may be any suitable type of valves, such as any of the bi-stablevalves described herein, a binary valve or a variable orifice valve. Thevalves 4204A, 4204B, 4204C of the module 4200 are controlled by acontroller 4206. The controller 4206 commands the valves 4204A, 4204B,4204C to particular valve states. The schematic diagram also includes apumping chamber 4202 and control chamber 4208 separated by adisplaceable barrier 4205 similar to those described elsewhere in thespecification (such as, e.g. a flexible diaphragm or membrane). Thepumping chamber 4202 may be bounded by a flexible membrane and can bepart of a removable or disposable fluid pumping cassette, and thecontrol chamber 4208 may be part of a pneumatic pumping device (a baseunit) configured to deliver pneumatic pressure to the cassette (orhydraulic pressure in some embodiments).

As shown, a first positive pressure input 4275, a second positivepressure input 4277 (which may be at a higher positive pressure than thefirst positive pressure source 4275), and a negative pressure input 4280are included. By actuating the valves 4204B in an appropriate manner,positive or negative pressure may be supplied to the control chamber4208. Additionally, valve 4292 and valve 4294 to the pumping chamber3084 may also be controlled by appropriately actuating the valves 4204A.Thus fluid may be pumped from a source reservoir 4210 to a destinationreservoir 4212, or vice versa.

Pressure sensors (not shown) may be used to measure or monitor pressureassociated with valves 4204A, B as described above with reference toFIG. 36 . Pressure sensors 4224, 4226 may be used to measure or monitorpressure associated with valves 4204C. A first pressure sensor 4224 maybe associated with the control chamber 4208 to monitor or measure thepressure of the control chamber 4208. Its specific location is arbitraryas long as it can fluidly communicate with the control chamber. A secondpressure sensor 4226 may be associated a with reference chamber 4228 tomonitor the pressure of the reference chamber 4228. The referencechamber 4228 is designed to be a chamber of fixed or known volume. Thereference chamber 4228 optionally may be attached to or located on amanifold block 2804 (FIG. 34A) of a module 4200.

The controller 4206 receives and processes pressure data generated bypressure sensors 4224 and 4226. Data from pressure sensors 4224 and 4226may be used to determine the volume pumped or displaced over a pumpingstroke. In an embodiment, before the stroke begins, a valve 4204C isoperated to isolate the control chamber 4208 from the reference chamber4228. The reference chamber 4228 is pressurized, preferably to a desiredpressure. For example, the reference chamber 4228 may be placed in fluidcommunication with a vent 4230 by actuating a valve 4204C. The pressurein the control chamber 4208 and reference chamber 4228 are measured withrespective pressure sensors 4224 and 4226. The control chamber 4208 andreference chamber 4228 are placed in fluid communication with oneanother by opening two valves 4204C, and their pressures may be allowedto equalize. The equalized pressure is then measured using pressuresensors 4224 and 4226. Since the volume and pressure of the referencechamber 4228 is known and the pressure of the control chamber 4208 isknown, the change in pressure upon equalization can be used to determineusing ideal gas laws the volume of the control chamber 4208. The gaslaws may be modeled, for example, to provide a reasonable approximationof the change in volume of the control chamber (and therefore also thepumping chamber). The controller 4206 records the pre-stroke volume ofthe control chamber 4208. The controller 4206 then commands the stroketo be performed. The controller then determines the post-stroke volumeof the control chamber 4208. The post stroke control chamber 4208pressure change is used to determine the pre-stroke to post-strokecontrol chamber volume change. This change in volume will be ameasurement of the amount of liquid pumped during the stroke. Theon-board controller may be programmed to compute the volume of liquidpumped, and optionally this measurement may be reported by the on-boardcontroller via a communications bus to a master module or maincontroller. Alternatively, an external main or intermediate controllermay be tasked with performing the volume calculations by receivingpressure data via the on-board controller.

Other methods of measuring a volume of fluid pumped by a pump chambermay also be used. For example, such methods may include those describedin U.S. patent application Ser. No. 14/732,571, filed Jun. 5, 2015, andentitled Medical Treatment System and Methods Using a Plurality of FluidLines, Attorney Docket No. Q21 or U.S. patent application Ser. No.14/723,237, filed May 27, 2015, and entitled Control System and Methodfor Blood or Fluid Handling Medical Device, Attorney Docket No. Q22,which are incorporated by reference herein in their entireties.

Referring now to FIG. 38A, in some embodiments, an individual valvedmanifold module 4302 may be dedicated to fluid volume measurement in afluid pumping system 4300. As shown, a single such module 4302 may beconfigurable to allow volume measurements of at least one fluid pump.Use of such a dedicated measurement module 4302 may be desirable whenrelatively precise measurements of pumped volumes are needed. Adedicated measurement module avoids having to alter the construction ofthe valved manifold modules 4304 dedicated to controlling a pump, forexample. Alternatively, and as shown in FIG. 37 a valved manifold module4304 dedicated to operating a pump may include the hardware required forvolume measurement, and the controller 2854 of that module may performboth pumping and volume measurement operations.

A measurement valved manifold module 4302 may be paired with one or morepumping modules 4304. The measurement module 4302 may coordinateoperation with each paired pumping module 4304 and provide access to areference chamber and to a vent to measure fluid volumes pumped by thepaired pumping module(s) 4304. The pumping modules 4304 may be similarto those described above with reference to FIG. 34C, for example. Thepumping module(s) 4304 controller 2854 can be configured to communicatewith the measurement module 4304 controller 2854 over a communicationbus 2864. This communication may allow a pumping module 4304 controller2854 to signal the measurement module controller 4304 when it is time totake a measurement (e.g. before and after a stroke). Pressure sensors2862 of the measurement module 4302 may be in fluid communication withthe control chambers 4306 under the control of the paired pumpingmodules 4304. Additionally, pressure sensors 3862 of the measurementmodule 4302 may be in communication with at least one reference volumeor chamber 4308. The at least one reference volume or chamber 4308 is ofa known volume and may, for example, be disposed within or attached to amodule block 2804 (FIG. 34A) of the measurement module 4302. The atleast one reference volume or chamber 4308 may also be located externalto and connected with the module 4302.

The pneumatic block 2856 of the measurement module 4302 may includevarious pneumatic components of a module 2800 such as one or more valves2802 (FIG. 34A). The pneumatic block 2856 of the measurement module 4302may be commanded by the measurement module 4302 controller 2854 to placeeach of the at least one reference volumes 4308 into fluid communicationwith a vent 4310 or an associated control chamber 4306. The pneumaticblock 2856 of the measurement module 4302 may be also commanded by themeasurement module 4302 controller 2854 to isolate each of the at leastone reference volumes 4308. Volume measurements may be made as describedabove.

In some embodiments the pneumatic block 2856 may also be controlled toconnect the control chamber 4306 to the vent 4310. This may be done tobring the pressure of a control chamber 4306 closer the pressure whichwill be used to perform the next stroke. For example, if a fill strokewas just performed, the control chamber 4306 may be at a negativepressure. The pressure may be vented, for example, to ambient, before adeliver stroke at a positive pressure is performed. This may help toreduce depletion of pressure reservoirs feeding the modules.

Referring now to FIG. 38B, a detailed schematic of a measurement module4302 which is paired with a pumping module 4304 is shown. As mentionedabove, the measurement module 4302 may be incorporated into a manifoldand used to generate relatively precise measurements of pumped volumesmoved by the pumping module 4304. The module may include a manifold base2804 which includes a number of inlet ports. The inlet ports may connectto both a positive pressure line or bus 4316 and a negative pressureline or bus 4314. The positive and negative pressure lines 4316, 4314may supply pressure to the modules 4304, 4302, from pressurized gasreservoirs 4312A, 4312B. The inlet ports may also be connected toatmosphere 4310 and the control chamber 4306 of a diaphragm pump 4320controlled by the pumping module 4304. The module is thus arranged tocharge a reference reservoir with positive or negative pressure, or toset its pressure to atmosphere, and to provide a valved connection to acontrol chamber of a pump whose volume is to be measured using one ormore models based on the ideal gas laws.

The measurement module 4302 may include a first, second, third, andfourth valve assembly respectively labeled 2802A, 2802B, 2802C, 2802D.Each of the valve assemblies may be mounted to a receiving station onthe manifold base 2804. The measurement module 4302 may also include acontroller 2854 which is in electrical communication with the valveassemblies 2802A-D and configured to selectively actuate the valves2802A-D. The manifold base 2804 may include a fluid pathway whichfluidically connects the manifold inlet port communicating with thepositive pressure bus 4316 to an inlet port of valve assembly 2802B. Themanifold base 2804 may include a fluid pathway which fluidicallyconnects the manifold inlet port communicating with the negativepressure bus 4314 to an inlet port of valve assembly 2802C. The manifoldbase 2804 may include a fluid pathway which fluidically connects themanifold inlet port communicating with atmosphere to an inlet port ofvalve assembly 2802D. The manifold base 2804 may also include a fluidpathway which fluidically connects the manifold inlet port incommunication with the control chamber 4306 to an inlet port of valveassembly 2802A. The manifold base 2804 may also connect the valvecavities of each valve 2802A-D to respective sensing ports or wells inthe manifold base 2804 as well as to a reference volume, chamber orreservoir 4308 of known volume. The controller 2854 may actuate thevalves to selectively open or close communication between the valvecavities of each valve 2802A-D and the inlets of each valve 2802A-D.

The controller 2854 may include a number of pressure sensors 3018 (FIG.36 ), for example a first, second, third, and fourth pressure sensor.During assembly of the measurement module 4302, the pressure sensors mayform a reversible sealed connection with respective sensing ports in themanifold base 2804. The controller 2854 may actuate or operate the valveassemblies 2802A-D to charge the reference chamber 4308 to a pre-chargepressure, for example with positive of negative pressure for pressurelines 4314, 4316. The controller may actuate or operate the valveassemblies 2802A-D to open the reference chamber or reservoir 4308 toatmosphere 4310. The controller 2854 may actuate the valve assemblies2802A-D to fluidically connect the reference volume 4308 to the controlchamber 4306 of the diaphragm pump 4320 to equalize pressure between thecontrol chamber 4306 and the reference chamber or reservoir 4308. Thecontroller 2854 may also monitor the pressure from the pressure sensorsin communication with the valve cavity of one or more valve assemblies2802A-D. The controller 2854 may record pressures from the monitoredpressure sensors before and after equalization. The pressure change maybe used to determine the volume of liquid pumped by the pump via thepumping module 4304 by calculating an initial and final volume throughthe pressure measurements of the reference chamber and control chamberof the pump.

The valve assemblies 2802A-D may be any suitable type of valveassemblies. In the example, the valve assemblies 2802A-D are bi-stablethree-way valves similar to many of those described elsewhere herein. Asshown, only one inlet port for each of the valves assemblies 2802A-D isused. The other of the inlet ports is blocked off or occluded asindicated by the encircled “B” connected to an inlet port of each of thevalve assemblies 2802A-D in FIG. 38B. The outlets of the valveassemblies 2802A-D are in fluidic connection with the referencereservoir or chamber 4308.

Referring now to FIG. 39 , a portion of a manifold 4500 including aregulator module 4502 is depicted. A regulator module 4502 may regulatethe pressure of a pneumatic bus to a second or regulated pressure whichis different from that of the pneumatic bus. This may be accomplished bytoggling a valve in the pneumatic block 2856 of the regulator module4502 which separates the pressure bus from a separate chamber or anaccumulator 4508, 4510. The pressure of the accumulator 4508, 4510 maybe sensed by a pressure sensor 3018 (FIG. 36 ) which is monitored by thecontroller 2854 of the regulator module 4502. The controller 2854 maytoggle the valve using data from the pressure sensor. For example, thecontroller 2854 may command the valve to toggle to place an accumulator4508, 4510 in communication with the pressure bus when the sensedpressure of the accumulator 4508, 4510 falls below a first predeterminedvalue. The controller 2854 may command that the valve close offcommunication between the pressure bus and the accumulator 4508, 4510when the sensed pressure of the accumulator 4508, 4510 is above a secondpredetermined value.

In the example embodiment, the regulator module 4502 is in communicationwith a positive pressure bus 4504 and a negative pressure bus 4506. Theregulator module 4502 may regulate the pressure of the positive pressurebus 4504 to a lower positive pressure. The regulator module 4502 mayregulate the pressure of the negative pressure bus 4506 to a weakernegative pressure. In the example shown, ports 4502-1 and 4502-3 of theregulator module 4502 are in communication with positive pressureaccumulator 4508. Ports 4502-2 and 4502-4 of the regulator module 4502are in communication with negative pressure accumulator 4510.

The accumulators 4508, 4510 may be any suitable reservoir. In someembodiments, the accumulators 4508, 4510 may be identical. Theaccumulators may, for example, be rigid plastic or metal tanks and mayhave an interior volume between 500 ml and 2 L (e.g. 1 L).

Port 4502-3 may be an outlet port for a valve of the pneumatic block2856 controlling fluid communication between the positive pressure bus4504 and the positive pressure accumulator 4805. Port 4502-4 may be anoutlet port for a valve of the pneumatic block 2856 controlling fluidcommunication between the negative pressure bus 4506 and the negativepressure accumulator 4510. The valves associated with ports 4502-3 and4502-4 may be toggled by the regulator module 4502 controller 2854 basedon the sensed pressure of their respective accumulators 4508, 4510 asdescribed above.

In the example embodiment, ports 4502-1 and 4502-2 are not associatedwith valves. Instead, the pneumatic block 2856 may include pneumaticisolation members or assemblies in association with these ports 4502-1,4502-2. The pneumatic isolation members or assemblies are furtherdescribed later in the specification and in the example embodiment maypneumatically isolate the pressure buses 4504, 4506 from ports 4502-1,4502-2. These ports 4502-1, 4502-2 may be connected to a fluid volumesuch that the pressure sensors 3018 (FIG. 36 ) associated with the ports4502-1, 4502-2 may monitor the pressure of the fluid volume. In theexample embodiment, port 4502-1 is connected to the negative pressureaccumulator 4510 to periodically measure or monitor the pressure of thenegative pressure accumulator. Port 4502-2 is connected to the positivepressure accumulator 4508 to periodically measure or monitor thepressure of the positive pressure accumulator.

Additional modules 4512 of the manifold 4500 may draw from the pressureaccumulators 4508, 4510 and operate at the regulated pressure of theaccumulators 4508, 4510. This may be desirable, for example, if portionsof a fluid circuit controlled by a manifold 4500 operate at differentpressures. In embodiments in which the fluid circuit includes at leastone fluid handling cassette, the fluid valves of the cassette may beoperated at greater pressures than the pump chambers of the cassette.Additionally, pump chambers of a cassette or of a number of differentcassettes in a fluid circuit may be operated at different pressures.Modules 4512 controlling portions of the fluid circuit which operate atgreater pressure may be disposed upstream of the regulator module 4502and modules 4512 which operate at lesser pressures may be disposeddownstream of the regulator module 4502. Additionally, some embodimentsmay include a plurality of regulator modules 4502 allowing for a fluidcircuit to be operated at more than two sets of pressures.

FIG. 40 depicts an example embodiment of a pneumatic isolation assembly4600 which may be included in the pneumatic block 2856 of a module, forexample, a regulator module 4502 (FIG. 39 ). As mentioned above, apneumatic isolation assembly 4600 may isolate a pressure bus or busescommunicating with the module from the port with which the pneumaticisolation assembly 4600 is associated. Such a pneumatic isolationassembly 4600 may be associated with a port of any module if it isdesired that that port be used, for example, for sensing purposes. Inthe example shown, the pneumatic isolation assembly 4600 is a modifiedfluid valve. The pneumatic isolation assembly 4600 includes a gasketmember 4602. The gasket member 4602 does not include pressure inlets orports (see, e.g. 4112, 4114 of FIGS. 28A-28C). As a result, the gasketmember 4602 serves to block and isolate any pressure buses feeding intothe pneumatic isolation assembly 4600 from the module port associatedwith the pneumatic isolation assembly 4600.

In other embodiments, a pneumatic isolation assembly 4600 may not be amodified valve. Any suitable means of isolating the pneumatic buses froma module port may be used. For example, a block of gasketing materialmay be attached to a module in place of a valve. Plugs or a similarstructure may be coupled into the module or a fixative or glue may beused to seal off pneumatic ports. Alternatively, although a pneumaticisolation assembly 4600 may resemble a valve, certain components of thevalve may be absent. Components which are related to toggling of thevalve may be removed. For example, coil assemblies 4650 may not beincluded in a pneumatic isolation assembly 4600. Additionally, posts(see, e.g. 4104, 4106 of FIGS. 28A-28C), a shuttle (see, e.g. 4102 ofFIGS. 28A-28C), and an interior valve cavity (see, e.g. 4116 of FIGS.28A-28C) may be absent. A pneumatic isolation assembly 4600 may also beconstructed from different materials as magnetic flux paths within apneumatic isolation assembly 4600 are not a concern. In someembodiments, fasteners 4644 may not be included. Instead, a pneumaticisolation assembly may be a single block of material or may include anumber of pieces of material which may be snap fit, friction fit,solvent bonded, etc. together.

FIGS. 41A-41B depict an example embodiment of a manifold assembly 2950including a number of valve manifold modules 2900-1, 2900-2, 2900-3,2900-4 that have been installed in a cassette based fluid pumping system3390. Although this example employs a pneumatically driven pumpingsystem, a similar arrangement can be applied in a hydraulically drivensystem. A hydraulic system may vary in its configuration to allow forpump or valve actuators that can be driven in opposite directions byappropriately directed separate positive hydraulic pressure lines actingon the actuators in opposing directions, rather than the positive andnegative pressure lines acting on the same side of a membrane actuatordescribed in the following pneumatically driven system.

In the example embodiment, there are four valve manifold modules 2900-1,2900-2, 2900-3, 2900-4. Each of the modules 2900-1, 2900-2, 2900-3,2900-4 in the example may be substantially identical in size, locationof ports, and electrical connections in order to be swappable with oneanother. Each module 2900-1, 2900-2, 2900-3, 2900-4 may include asimilar electronic control board. Each module 2900-1, 2900-2, 2900-3,2900-4 also includes a block of electrically actuated pneumatic valves.The pneumatic valve blocks are similar to those described above. In thisexample, each pneumatic valve block includes four valves and an outletport for each valve. The outlet ports of the valves are labeled “n”av,bv, cv, dv in which “n” is the module number (i.e. 2900-“n”). Theportion of the cassette 3400 controlled by a particular port on themanifold 2950 is labeled correspondingly. For example, a fluid valvecontrolled by port “n”bv on the manifold 2950 would be labeled “n”bc onthe cassette 3400. Despite the valve modules 2900-1, 2900-2, 2900-3,2900-4 being substantially identical, the valve modules 2900-1, 2900-2,2900-3, 2900-4 perform a variety of functions and are applied in avariety of ways within the cassette based fluid pumping system 3390. Afirst side 3401 of the cassette 3400 is shown in FIG. 41A while asecond, opposing side 3403 of the cassette 3400 is shown in FIG. 41B.

In the example embodiment shown in FIGS. 41A-41B, modules 2900-1 and2900-2 are valve manifold modules which control fluid valves 1AC-1DC and2AC-2DC on the cassette 3400. Referring primarily to FIG. 41A, each ofthe fluid valves 1AC-1DC and 2AC-2DC may include a valve well 3410defined by a valve wall 3408. Within the valve well 3408 is a valve seat3412. The valve wall 3410 may be slightly proud of the valve seat 3412.A flexible sheet covers each valve well 3408 and seals against the topof the valve wall 3410. Application of pressure to the flexible sheetcauses the sheet to displace, but the seal against the valve wall 3410is maintained. Positive pressure causes the sheet to displace againstthe valve seat 3412 closing the respective fluid valve 1AC-1DC and2AC-2DC. Negative pressure draws the sheeting away from the valve seat3412, opening the fluid valve 1AC-1DC and 2AC-2DC and allowing fluid toflow through. Such fluid valves are further described in U.S. Pat. No.5,350,357 which is incorporated by reference herein in its entirety.

Referring again to both FIGS. 41A-41B, by commanding modules 2900-1 and2900-2 to apply pressure so that fluid valves 1AC-1DC and 2AC-2DC on thecassette 3400 are opened and closed in a desired manner, various fluidpathways in the cassette may be established or blocked. Valves 2BC and2CC may be opened/closed to control communication between a first fluidbus 3414 of the cassette 3400 and cassette ports 3406A associated witheach of those valves. Valve 1AC-1DC, 2AC, and 2DC may be opened/closedto control communication between a second fluid bus 3416 of the cassetteand cassette ports 3406B associated with each of those valves.

Modules 2900-3 and 2900-4 are pumping or chamber modules which controlfluid valves 3AC, 3BC, 4AC, 4BC of the cassette 3400. These valves 3AC,3BC, 4AC, 4BC act as inlet/outlet valves to or from the pump chambers3420A, 3420B of the cassette 3400. Outputs 3CV, 3DV, 4CV, and 4DV of themanifold assembly 2950 are arranged to apply pressure to flexiblesheeting spanning over pump chambers 3420A, 3420B of the cassette 3400as indicated by reference numbers 3CC, 3DC, 4CC, 4DC. This flexiblesheeting may act as the flexible wall or barrier 3088 described above inrelation to FIG. 36 . Outputs 3CV, 3DV, 4CV, and 4DV may supply pressureto respective control chambers 3082 (FIG. 36 ). This pressure may causea change in volume in the associated pumping chamber 3420A, 3420B andthus cause fluid to be pumped by the pumping chamber 3420A, 3420B of thecassette 3400.

The valve assembly providing output to 3CV can be arranged to access thepositive pressure line only, in which case the valve assembly providingoutput to 3DV can be arranged to access the negative pressure line only,or vice versa. Outputs 3CV and 3DV can subsequently be merged into asingle flowpath to the control port communicating with the flexiblemembrane overlying the pump chamber (3CC, 3DC). Access of a valveassembly to only one pressure line in a pumping module can be achieved,for example, by substituting an inlet gasket having no holecommunicating with the unwanted pressure line in the manifold module.Alternatively a two way valve connected to only one of the pressurelines may be used. The valve manifold module 2900-4 controlling thepumping chamber designated 4CC, 4DC, can be arranged in a manner similarto module 2900-3.

In some embodiments, the cassette 3400 may be used to pump fluid duringa dialysis therapy such as a peritoneal dialysis therapy. In suchembodiments, the cassette ports 3406B associated with fluid valves1AC-1DC may each be connected to a reservoir (e.g. a bag) of dialysatesolution. The cassette port 3406A associated with fluid valve 2BC of thecassette 3400 can be connected to a heated reservoir (e.g. a bag on aheating tray). The cassette port 3406A associated with fluid valve 2CCof the cassette can be connected to a drain or waste reservoir. Thecassette port 3406B associated with fluid valve 2DC of the cassette 3400can be connected to a fluid line leading to the peritoneal cavity of apatient. The modules 2900-1, 2900-2, 2900-3, 2900-4 may be controlled byan on-board controller or an external controller (or combination of thetwo) such that fluid is transferred through the cassette 3400 toadminister a dialysis therapy. For example, modules 2900-1, 2900-2,2900-3, 2900-4 may be controlled so that fluid is transferred from asolution reservoir to the heated reservoir. The modules 2900-1, 2900-2,2900-3, 2900-4 may be controlled so that fluid is transferred from theheated reservoir to the patient. The modules 2900-1, 2900-2, 2900-3,2900-4 may be controlled so that spent fluid is transferred from thepatient to the drain or waste reservoir. Further description on how sucha cassette may be used to transfer fluid for a dialysis therapy may befound in U.S. patent application Ser. No. 14/732,571, filed Jun. 5,2015, and entitled Medical Treatment System and Methods Using aPlurality of Fluid Lines, Attorney Docket No. Q21 which is incorporatedby reference herein in its entirety.

As mentioned above, the modules 2900-1, 2900-2, 2900-3, 2900-4 may, insome embodiments, control operation of the cassette to transfer fluidfrom one cassette port to another autonomously (i.e. via a suitablyprogrammed on-board controller in the valve manifold module).Alternatively, the modules 2900-1, 2900-2, 2900-3, 2900-4 may receiveonly high level commands from a main controller of the fluid pumpingsystem 3390. Such commands may include, for example, a command to startpumping, stop or pause pumping, pump from a solution line to a heaterbag, pump from a heater bag to a patient line, pump from a patient lineto a drain line, etc. The on-board controller in turn can be programmedto coordinate the cassette valves and pumps to fulfill the high levelcommands. The on-board controllers of the modules 2900-1, 2900-2,2900-3, 2900-4 may also communicate and coordinate operations amongthemselves to accomplish the high level commands with minimal or nofurther input from the main controller.

FIGS. 42A and 42B depict an example embodiment of a manifold assembly2950 including a number of valve manifold modules 2900-1, 2900-2,2900-3, 2900-4 that have been installed in a cassette based fluidpumping system 3430. FIG. 42A shows the manifold assembly 2950 and thefirst side 3434 of a cassette 3432. FIG. 42B shows the manifold assembly2590 and a second, opposing side 3436 of the cassette 3432. The manifoldassembly 2950 is similar to that shown in FIGS. 41A and 41B, however,the cassette 3432 has a different arrangement of flow paths, valves andports. The cassette 3430 may, however, be operated in generally the samemanner as that described above in FIGS. 41A and 41B. Modules 2900-2,2900-3, 2900-4 are arranged as valve control modules which operate thefluid valves 2AC-2DC, 3AC-3DC, 4AC, and 4BC of the cassette 3430. Module2900-1 is arranged as a pump chamber control module. In the exampleembodiment, the pump chamber control module 2900-1 does not controlinlet/outlet valves to the pump chambers 3438A, B of the cassette 3432.Instead, the chamber control module 2900-1 supplies pressure to thecontrol chambers 3082 (FIG. 36 ) of a base unit of the system, providingpressure to the membrane overlying the pumping chambers 3438A, 3438B ofthe cassette. Two valve assemblies on the module supply pressure to onepump chamber—one positive pressure and the other negative pressure. Bycoordinating operations of modules 2900-1, 2900-2, 2900-3, 2900-4 withinthe manifold 2950, fluid may be pumped through the cassette 3432 to andfrom the various ports 3440 of the cassette 3432. In some embodiments,this may be done, for example, to perform a dialysis therapy such as aperitoneal dialysis therapy. Further description on how such a cassettemay be used to transfer fluid for a dialysis therapy may be found inU.S. Pat. No. 5,350,357, issued Sep. 27, 1994, and entitled PeritonealDialysis System Employing a Liquid Distribution and Pumping Cassettethat Emulates Gravity Flow which is incorporated by reference herein inits entirety.

FIGS. 43A and 43B depict an example embodiment of a manifold assemblyincluding a number of valve manifold modules that have been installed orconcatenated together for use in a hemodialysis system. The valvemanifold modules may be concatenated in a single bank, or a smallersubset may be concatenated into a manifold bank, with a number ofmanifold banks stacked one above the other to optimize the spaceoccupied by the manifold assembly. Each bank can be arranged to haveported access to positive and negative pressure lines. In the exampleembodiment there are 11 valve modules with the first valve module beingthe leftmost module and the 11^(th) valve module being the rightmostmodule. Each of the modules in the example may be substantiallyidentical. Each module may include substantially the same programmableelectronic control board. Each module also includes a pneumatic manifoldblock. The pneumatic blocks are similar to those described above. Inthis example, each pneumatic block includes four valve assemblies and anoutlet port for each valve to form a valve manifold module. Each of theoutlet ports is labeled “n”a-d in which “n” is the module number. Theportion of the dialysis circuit controlled by a particular port on themanifold is labeled correspondingly. For example, a valve controlled byport “n”b on the manifold would be labeled “n”b on the dialysis circuit.The pneumatic lines connecting the ports of the manifold to the dialysiscircuit are not depicted for the sake of clarity of illustration.Despite the valve modules being substantially identical, the valvemodules perform a variety of functions and are applied in a variety ofways within the dialysis machine, each said function being determined atleast in part by the location of the module along the manifold assembly.

A valve manifold assembly that controls the operation of a membrane pumpmay comprise a valve assembly that switches between access to positiveor negative pressure for an inlet flow valve of the membrane pump, asimilar valve assembly for an outlet flow valve of the membrane pump, avalve assembly having access to a positive pressure line, and a valveassembly having access to a negative pressure line, the latter two valveassemblies configured to control operation of the pump membrane. Accessof a valve assembly to a pressure line can be denied relative simply,for example, by replacing a gasket between the valve assembly and thepressure lines with a gasket having only one access port to either onepressure line or the other.

A power and a communication bus may optionally extend from module tomodule throughout the manifold. In an embodiment, the communications busis configured similar to a CAN-bus, in which disruption of one modulealong the chain may disrupt communications to the downstream modules.However, the power bus to all modules may remain intact so that any ofthe downstream modules may remain operational. In certain locationsalong the manifold assembly, the module may be pre-programmed to enteran autonomous mode of operation for a designated period of time uponloss of communications, so that a blood pump, for example, may continueto operate when an upstream module fails or is disconnected.

Additionally, negative, high positive, and low positive pressurepneumatic buses extend from module to module throughout the manifold.Each module includes an on-board processor which commands the valvedpneumatic block of the module and sends signals to actuate the valves ofthe module. Additionally, each processor receives pressure data fromfluid flow paths in the pneumatic block, so that, for example, thepressure of the pumping chambers of each pump in the system can bemonitored by the valve manifold module control boards. Each module alsoincludes a generic connector which allows the module to be connected toany of a variety of peripherals. For example, any of a variety ofsensors may be connected to the module via the generic connector. Datafrom a connected peripheral device may be conveyed to the processor ofthe module. In FIGS. 43A and 43B, signals coming from peripheral devicesin the dialysate circuit are labeled “n”s“#” where “n” is the module towhich the peripheral device is connected, s is an abbreviation for theword signal, and # is an identifier for the peripheral device todistinguish between peripheral devices when more than one peripheraldevice is connected to an individual module.

As shown, module 1 is connected to the dialysate machine circuit suchthat only two of its outputs 1 a and 1 b are used. The other ports ofthe module are blocked off. 1 a and 1 b control two pneumatic orhydraulic occluders in the example diagram. The occluders may bebladders or a piston/cylinder arrangement which may be actuated withpositive pressure to cause displacement of an occluder blade thatcontacts the fluid line to open the associated fluid line. The occluderscontrolled by 1 a and 1 b may be spring-biased and used to respectivelyocclude (through, e.g., release of pressure) an arterial line from apatient and a venous line to the patient.

As shown, in an optional arrangement, module 1 also receives a signalfrom two peripheral devices in the dialysis machine. The first signal, 1s 1, is generated by an air-in-line sensor installed on the arterialline of the dialysis machine circuit. The second signal, 1 s 2, isgenerated by a second air-in-line sensor installed on the venous line ofthe dialysis machine circuit. The processor of module 1 may monitorsignals 1 s 1, and 1 s 2 from the air-in-line sensors. In response adetermination that a signal indicates there is air in at least one ofthe lines, the processor of the module may issue commands to the valvesto cause the pneumatic occluders to deploy. Thus based on 1 s 1 and 1 s2, the module may release the occluder bladders to block fluid flow andprevent air from reaching the patient.

Module 2 and 3, which can be substantially the same as any other modulein the manifold, are used to control fluid pumping within the system. Asshown, module 2 and module 3 operate their valves to pump fluid in a twochamber fluid pump. This pump is similar to the two chamber fluid pump2896 of FIG. 34F. In the example of a hemodialysis machine, it may bedesirable that the two chambers be operated such that fluid is pumped ina substantially continuous fashion. This may require coordinationbetween the on-board controllers of modules 2 and 3 as signified by thebracket grouping the two blood pump modules (2 and 3) on the manifold.The on-board controllers of modules 2 and 3 may communicate with oneanother over the communication bus of the manifold to synchronizepumping. Specifically, for example, the modules may coordinate pumpingoperations such that one blood pump is filling its fluid pumping chamberwhile the other module is delivering its fluid pumping chamber.

The blood pumps may pump blood through a dialyzer of the hemodialysissystem, which is designed to extract substances such as creatinine,urea, etc. from the blood. The modules may control the two chambers ofthe fluid pump to pump blood at a desired rate based on coordinatedcommands from their respective processors.

Modules 4 and 5 are also used to control fluid pumping within thedialysis machine circuit. In the example in FIG. 43A, modules 4 and 5are dialysate pumps which control the pumping of dialysate through thedialyzer. As above, a bracket grouping modules 4 and 5 indicates thatthe modules may coordinate operations with one another to ensure thatdialysate is pumped in a specified manner.

Module 6, also configured as a pump in FIG. 43B, may control anultrafiltrate pump of the dialysis machine circuit. Module 6 mayoptionally control the UF pump to draw fluid out of the patient's bloodas commanded by the system controller.

Modules 7 and 8, which again can be substantially identical to everyother module in the manifold, are used as pneumatic valve controllerswhich serve to operate valves of a balancing circuit of the dialysismachine circuit. Modules 7 and 8 may control the valves in the balancingcircuit to ensure that the amount of fresh dialysate flowing to thedialyzer is substantially equal to the amount of spent dialysate flowingfrom the dialyzer. The balancing circuit valve modules are groupedtogether to indicate that these modules coordinate operations to ensureproper function of the dialysis machines balancing circuit. As shown,the grouped dialysate pump modules and the grouped balancing circuitvalves may also coordinate operations. This may allow the dialysatepumps and balance circuit valves to work effectively together in a fullycoordinated manner.

Modules 9 and 10, which are configured as to operate fluid pumps arealso shown as a group of modules whose on-board controllers maycoordinate operations with one another. As shown in FIG. 43B, modules 9and 10 control the pumping of fluid by another two chamber fluid pump.The two chamber fluid pump is a dialysate delivery pump is a pump whichpumps fluid through a heater element and to the balancing circuit of thedialysis machine. As described above in relation to modules 2 and 3,modules 9 and 10 may coordinate pumping operations to cause dialysate topump in a substantially continuous manner.

Module 11, in the example embodiment, is shown as controlling a numberof routing valves. These valves may route fluid entering the depictedcircuit (e.g. from a mixing circuit) to a plurality of destinations. Thevalve controlled by module output port 11 a controls a venting pathwayfor the dialysate reservoir. The valve controlled by module output port11 b may be opened or closed to allow or prevent fluid flow into thedialysate reservoir or tank. The valve controlled by module output port11 c may be opened or closed to allow or prevent fluid flow to a drainline or drain destination. The valve controlled by 11 d also may beopened or close to make or break a flow path to a drain line. In someembodiments, only one valve is required to coordinate flow through asingle line to drain.

As shown, module 11 also receives a signal from two peripheral devicesin the dialysis machine. The first signal, 11 s 1, is generated by alevel sensor installed on or in the dialysate tank or reservoir of thedialysis machine circuit. This level sensor may be any suitable varietyof level sensors. In various embodiments, the level sensor may be, butis not limited to, a capacitive sensor, optical sensor, float sensor,rangefinder, etc. The controller of module 11 may monitor the signal 11s 1 and open the valve controlled by output port 11 b to allow dialysateto flow into the dialysate reservoir when the level sensor indicates thedialysate volume in the reservoir has dropped below a threshold value.The valve controlled by 11 a may also be opened at this time to allowfor air to be displaced out of the reservoir as new dialysate enters thereservoir. In some embodiments, signal 11 s 1 may also be conveyed tomodules 9-10 such that the valve may be opened when fluid is pumped outof the dialysate reservoir to allow air to replace the fluid beingremoved. Alternatively, modules 9-10 may coordinate with module 11 toaccomplish the same task. In the event that signal 11 s 1 indicates thatthe reservoir is has a dialysate volume above a threshold value, thevalve controlled by module output port 11 b may be commanded closed andthe valve controlled by module output port 11 c and/or d may becommanded open. Thus any excessive dialysate will be dumped to drain.

The second signal, 11 s 2, is generated by a conductivity sensorinstalled on the fluid line coming from a mixing circuit (not shown).The processor of module 11 may monitor signal 11 s 2 from theconductivity sensor. In response a determination that the signalindicates the dialysis solution entering the depicted circuit is notsuitable for use (e.g. due to a mixing problem) the controller of themodule may issue commands to close the valve controlled by output port11 b and open at least one of the valves controlled by output port 11 cor d. Thus the unsuitable dialysate may be prevented from entering thedialysate reservoir and may instead by diverted to drain.

FIG. 44 depicts a flowchart outlining an example procedure 3100 forinitiating automatic enumerating or assigning of unique identifiers tomanifold modules in a manifold assembly. The assignation may be mediatedby an on-board controller of the module via a connection to a commonelectronic communications bus. The procedure 3100 may begin with amanifold module being designated 3101 a master module. The master modulemay in some embodiments, be designated the master module by a hardwareswitch on a PCB of the manifold module. This switch may be toggled todesignate a module as a master module. Alternatively, a module may bedesignated a master module by programming the controller of the moduleto designate the module as a master module. For simplicity, the mastermodule may generally be at an end of a communications bus, for example,the first module on the communications bus. Each module may be connectedto power from a power bus and defaulted to a configuration in whichcommunication in a direction along a communications bus with anyadditional modules in has been disabled 3102. For purposes of example,this direction will be referred to as a downstream direction. The mastermodule controller may assign itself a unique identifier. For example,the master module may enumerate 3103 as module 1. The master module mayestablish downstream communications 3104 to the next module of thecommunications bus. The master module broadcasts 3106 its moduleidentifier on the communications bus. In an exemplary implementation,this broadcast may be performed for a predetermined period of time, forexample, 20-100 ms.

FIG. 45 depicts a flowchart outlining an example procedure 3110 forautomatically enumerating or assigning unique identifiers to manifoldmodules on a communications bus. A slave module first powers on 3112.The slave module controller becomes receptive 3114 to communications onthe communication bus. In some exemplary implementations, the slavemodule controller may be in a receiving mode 3114 to the communicationsbus for a predetermined period of time. This period of time may, forexample, be 50-100 ms. The slave module controller may determine 3116the value of the last claimed unique identifier. For example, the slavemodule controller may save the highest identifier received whilereceiving messages on the communications bus. The slave modulecontroller may assign itself 3118 as the next available uniqueidentifier. In an example, the next available unique identifier may bedetermined by adding one to the saved highest identifier. For example,if the highest identifier received is 1, the slave module controllerwould assign itself as module 2. The slave module may establishdownstream communication 3120 with the next module. The slave module canthen broadcast 3122 the unique identifier it assigned itself.

The next slave module controller may in turn become receptive 3124 tocommunications on the communications bus. The controller of the nextslave module determines 3126 the last claimed unique identifier whilebeing receptive 3124 to the communications bus. This identifier shouldbe the identifier just assigned to the previous module. The slave modulecontroller may then assign 3128 itself the next available uniqueidentifier. The slave module may establish downstream communication 3130with the next downstream module. The slave module controller transmits3132 its unique identifier on the communications bus. If 3134 there areadditional modules, the procedure 3110 may return to 3124 and repeat,allowing any additional modules on the communications bus to assignthemselves a unique identifier.

FIG. 46 depicts a flowchart outlining an example procedure 3140 forenumerating or assigning a unique identifier to a module which isinstalled onto a communications bus which has already been enumerated.Such a procedure 3140 may, for example, be used in the event that a bankof manifold modules of a manifold assembly needs to be expanded or whena module is swapped/replaced. The new module may be installed 3142 intothe manifold assembly and connected to the communications bus. The newmodule controller can send a query 3144 to the master controllerrequesting the number of modules on the bus. The master modulecontroller sends an appropriate response 3146 on the communications bus.The new module controller receives 3148 the response and sends 3150 aquery on the communications bus requesting other modules to send theirrespective IDs. Each module controller can send a response 3152 on thecommunications bus specifying their ID. The new module controller isplaced in a receiving mode on the communications bus and saves 3154 theIDs received. The new module controller can then compare 3156 thereceived IDs to the number of modules on the communications bus. Basedon the comparison, the new module controller can determine and assignitself 3158 the appropriate identity. For example, if the new modulecontroller receives 3148 a response that there are 10 modules on the busand the new module controller saves 3154 identifiers for every moduleexcept module 7, the new module can assign itself 3158 as module 7.Alternatively, if the new module controller, for example, receives 3148a response that there are 10 modules on the bus and the new modulecontroller saves 3154 identifiers for modules 1-10, it may assign 3158itself as module 11.

Optionally, the new identity may be transmitted on the communicationsbus by the new module controller. During this transmission thecontrollers of modules on the communications bus can check the newmodule unique identifier against their own and generate an error if theunique identifier matches their own. Additionally, the master modulecontroller can save the new module unique identifier and update thetotal number of modules on the communications bus if necessary.

FIG. 47 depicts a flowchart outlining an example procedure 3160 whichmay be used to assign tasks to various modules in a manifold assembly.In the example procedure 3160, the main controller may havepre-programmed tasks for a number of different manifold modules. Inother embodiments, the tasks may be pre-programmed onto a master modulecontroller and input from a main controller need not be employed. Themain controller can send 3162 a query to the master module controllerrequesting the number of modules on the communications bus. The mastermodule controller may send 3164 a response indicating the number ofmodules on the communications bus. The main controller can then compare3166 the number of modules specified by the master controller to anexpected number of modules. If 3168 the expected number of modules isgreater than the number reported by the master module controller, themain controller may enter an error state and generate a notification3170 for display on a user interface of the device in which the manifoldassembly is used. In some embodiments, the main controller may enter anerror state if the number of modules reported by the master modulecontroller differs from the expected number. For example, an error statemay be entered and a notification generated if the master modulecontroller indicates that extra modules are present.

If 3168 the expected number of modules matches the number reported bythe master module controller, the main controller can proceed todetermine 3172 a task or task set for the first manifold module. Themain controller can send a task command 3174 to the first module. Uponreceipt, the first module controller may configure 3176 the module forthe specified task or set of tasks. If 3178 there are no furthermodules, the task assignment process can end. If 3178 there areadditional modules, the main controller determines 3180 the task set ofthe next module. The main controller can send a task command 3182 to thenext module and upon receipt, that module controller may configure 3184its module accordingly. If 3178 there are no further modules, the taskassignment process can end. If 3178 there are additional modules, 3180,3182 and 3184 may repeat until all modules have been assigned a taskset.

The task command generated by the main controller may, in someembodiments, be a high level command. For example, in embodiments inwhich the modules control pneumatic pathways leading to a pumpingcassette, the task command may specify that a manifold module be a pumpchamber module or a fluid valve module, or a combination of the two. Inan exemplary implementation, the recipient module controller mayinterpret this task command and automatically set its program for valveconfigurations, sequencing and default states accordingly.Alternatively, the task command may provide specific valve configurationinformation to a module. For example, a task command may includeconfiguration settings for individual valves of the module. The taskconfiguration command may, for example, specify a module number, valvenumber (e.g. 1-4), and configuration setting. Each manifold module maybe configured to accept a plurality of valve assemblies. In a preferredembodiment, the number of valve assemblies per module is standardized topermit ready replacement or substitution of a valve assembly and gasketat an assigned location in the module, or ready replacement of theentire module without necessitating re-programming of the modulecontroller. In some cases, the gasket mating a particular valve assemblyto the fluidic bus (pneumatic or hydraulic) may have differentcommunication holes or ports to the bus to permit or deny access of thevalve to a particular pressure line in the bus. A non-limiting number ofexample configuration settings are shown in TABLE 1 as follows:

TABLE 1 Valve Configurations Description Fluid 3 way valve with an inputconnected to positive Valve pressure and an input connected to negativepressure Chamber 2 way valve with an input connected to positivepressure Valve Pos Chamber 2 way valve with an input connected tonegative pressure Valve Neg Regulator Valve which outputs to anaccumulator and toggles to regulate a source pressure to an accumulatorpressure Vent Valve which is connected to a vent reservoir or atmosphereMeasurement Valve arranged to make and break fluid communication Valvebetween a reference volume and a control chamber Blocked Valve which isin a module but unused and has had its ports blocked offOptionally, each module may default to predetermined valve configurationsettings. In such embodiments, the main controller may not generate atask command for a module if the default settings are appropriate forthe task set. In some specific examples, each module may default to apump chamber control module configuration in which two valves of themodule are configured as fluid valves, one is configured as a positivechamber valve, and another is configured as a negative chamber valve.

Optionally, task commands may include primary or grouped task setsaddressed to a master module controller. Any of the module controllersin a manifold assembly may be assigned to be a master module controller.The master module controller can receive a primary or grouped task setassignment from a main or system controller via the communications bus.The primary or grouped task command set may assign a master module atask set to coordinate the tasks of a specific secondary module or groupof secondary modules. For example, in some embodiments, the primary orgrouped task command set may specify that the master module controllercoordinates or synchronizes pumping performed by two or more pumpchamber modules (e.g. pump chamber modules controlling two or more pumpchambers of the same device or the same pump cassette). This may causethe specified secondary modules to effectively operate in tandem toprovide the pumping device with greater potential throughput. Such agrouped task assignment may allow the main controller to transmit asingle command set with a group identifier. The master controller of theprimary module can receive this command or set of commands and transmitindividual commands or tasks to secondary modules associated with thegroup identifier to execute the main controller command set. Althoughtiming of inlet and outlet pump valve operations with an associated pumpoperation can be performed locally with the on-board controller of theindividual pump control modules, synchronizing the operation of onepump/valve combination with another pump/valve combination may be afunction of the group command set coordinated by the master controller.The master controller may be a program installed on any of the on-boardcontrollers of the valved manifold modules. Optionally a mastercontroller may not be used. Instead a controller external to themanifold assembly, such as a main or system controller may perform thefunctions of a master controller.

Another primary task command set may specify that the master modulecontroller coordinate operations of a pump chamber module with a volumemeasurement module (e.g. a manifold module having a valved connection toa reference chamber and to vent for pressure/volume calculations). Thismay cause the master module controller to synchronize operations of thevolume measurement module with the pump chamber module so that thevolume measurement module performs a pressure measurement to determinethe volume transferred in each pump stroke commanded by the pump chambermodule.

FIG. 48 depicts a flowchart outlining an example procedure 3200 forcommanding operation of a module. The main controller generates acommand or set of commands and transmits the command 3202 to the mastermodule controller. The master module controller receives 3204 thecommand. If 3206 the command is for valves on the master module, themaster module controller commands execution 3208 of the command. If 3206the command is for a slave or secondary module, the master modulecontroller transmits 3210 the command on the communication bus with therecipient module address. The recipient module controller monitors thecommunication bus and receives 3212 the command. The recipient modulecontroller then executes 3214 the command.

In some cases, the command may flow directly from the main controller tothe recipient module depending on the type of command. For example, ifthe command does not require coordination between multiple modules, thecommand may be read directly by the recipient module and acted upon.

FIG. 49 depicts a flowchart outlining an example procedure 3220 fortransmitting feedback data from a valve module to a main controller. Amodule executes a task 3222 and generates data 3224. This data may besensor data (e.g. pressure sensor data) generated by a sensor on themodule as the task is executed. The data may also be data generatedafter execution of a task. For example, the data may be valve state datawhich specifies the current status of the valve (e.g. valve in firstposition or second position, valve open, valve closed, etc.). The modulecontroller sends the data 3226 on the communications bus. In an example,data may be sent based on a predetermined schedule, for example, every90-110 ms (e.g. every 100 ms). The main controller receives 3228 thedata from the communications bus. Optionally, both the master module andany slave modules on a communications bus may provide feedback in thismanner.

The master module may also receive data from other modules on thecommunications bus. This is useful in circumstances in which the mastermodule controller coordinates operations between modules on thecommunications bus. FIG. 50 depicts a flowchart outlining anotherexample method 3230 for providing feedback from a module. A moduleexecutes a task 3232 and generates data 3234. The module transmits thedata 3236 on the communications bus. Data may be sent based on apredetermined schedule, for example, every 90-110 ms (e.g. every 100ms). The master module controller receives 3238 the data from thecommunications bus, and passes 3240 the data to the main or systemcontroller. Alternatively, both the master module controller and themain controller can receive the data when the modules transmit it.

The master module controller may be programmed to perform some degree ofsignal processing before it passes 3240 data to the main controller. Forexample, the master module controller may report data at a slower ratethan the data it receives. It may send a summary or synopsis to the mainor system controller. It may filter the data, or average a series ofdata points over a predetermined period of time and pass the filtered oraveraged values to the main controller based on a predetermined scheduleor time interval. In some exemplary implementations in a manifold systemdriving a fluid pumping cassette, pressure data related to the one ormore pump chambers and valve state data may be transmitted to the maincontroller, and pumping chamber related data may be transmitted to boththe main controller and the master module controller. Additionally, amaster module controller or the main or system controller may generate aquery requesting information (e.g. valve state data) from a specificmodule controller.

FIG. 51 depicts a flowchart outlining an example procedure 3250 ofcommanding operation of a valve within a valve module. The maincontroller sends a valve state command 3252 over the communications bus.This command may specify a valve state and be addressed to a specificvalve in a specific recipient module. The controllers of the modulesmonitor the communications bus and the recipient module receives thecommand 3254. The recipient module processor enables current flow 3256through valve coils of the appropriate valve in a direction suitable toexecute the valve state command. The recipient module sends feedbackdata 3258 on the communications bus. In some exemplary implementations,this data may be sent continuously or periodically on a predeterminedschedule over the communications bus. For example, data may be sentevery 90-110 ms.

FIGS. 52A-52B depicts a flowchart outlining an example procedure 3260 ofa valve manifold module actuating the pumping of fluid through a pumpchamber of a cassette. For sake of simplicity, the flowchart outlinespumping via a single valve manifold module, but a plurality of modulesmay also be employed to actuate a single pump chamber of a cassette(see, e.g. FIG. 34G). In the example provided, the pumping command setis directed to one or more slave modules on a manifold assembly. A maincontroller transmits a pumping command 3262 over the communications bus.The pumping command may be a high level command. For example, thepumping command may be a start/resume pumping or stop/pause pumpingcommand and may specify a pumping flow rate. The command may alsospecify one or more pumping targets. For example, the high level commandmay specify a duration of pumping, number of pumping strokes, and/orvolume to be transferred. The pumping command may also specify a sourceand a destination for the fluid being pumped. A master module in a bankof manifold modules may be tasked to receive and process 3264 the highlevel pumping command set.

The master module controller transmits 3266 a chamber pump command withan appropriate module address. The chamber pump command specifies that aspecific module toggles its valves to trigger a fill stroke or adelivery stroke of a pumping chamber, or that pumping from a pumpingchamber is to be stopped or paused. In the example shown, the mastermodule controller transmits 3266 a fill chamber command addressed to arecipient module. Slave modules monitor the communications bus and therecipient module receives the chamber fill command 3268. The recipientmodule executes the chamber fill command by generating one or more valvecommands. Since the chamber command is a fill chamber command in theexample, the slave module controller toggles the manifold valvescontrolling the inlet and outlet pump chamber valves to the appropriatepressure line on the pneumatic bus, and commands the pump chambercontrol valves to toggle so that the positive pressure manifold valve isclosed and the negative pressure control valve is opened 3270. The inletand outlet control valves are toggled to place the pump chamber of thecassette in communication with a fluid source. Toggling open thenegative pressure manifold valve results in the application of negativepressure to the pump chamber, drawing fluid into the chamber fluid fromthe fluid source. The slave module controller optionally monitorspressure data 3272 sensed by a pressure sensor monitoring the pressuresupplied to the pump control chamber of the pump cassette. If 3274 anend-of-stroke is detected from the pressure data, the controller of theslave module performing the pumping stroke can report the end-of-strokecondition 3276 on the communications bus. If 3274 end-of-stroke has notyet been detected the slave module controller continues monitoringpressure data 3272. In some aspects, the slave module controller mayreport the end-of-stroke condition 3276 by indicating that it is in anidle state. In some aspects, the slave module controller may also beprogrammed to calculate or determine the flow rate during the stroke andreport the result on the communications bus. This may be calculated aspump chamber volume over the time elapsed during the stroke before anend-of-stroke condition is detected. If the pumping module is pairedwith a measurement module or has integral volume measurement hardware(such as, e.g. a valved reference chamber, or valved communication tovent), a measurement of the volume pumped over the stroke may be taken.This measurement may be reported over the communications bus and can beused to calculate overall flow rate of the pumping cassette or of apumping chamber.

The master module controller may receive the signal indicating theend-of-stroke condition and issue a command 3278 for pumping tocontinue, pause or stop. In the example provided, since a fill strokewas just performed, the master module controller may command for adeliver stroke to be performed, or alternatively may withhold a stop orpause command, and the on-board controller of the pump module mayproceed as programmed to perform a deliver stroke. The recipient slavemodule controller monitors the communications bus and receives thedeliver chamber command 3280, or alternatively proceeds with itspre-programmed deliver stroke in the absence of a contrary command fromthe master module controller or the main or system controller. The slavemodule controller toggles the inlet and outlet control valves of themodule to the appropriate positive or negative pressure lines to directpumping to the appropriate fluid delivery destination, and commands thechamber valves to toggle so that positive pressure is supplied 3282 tothe pump control chamber. The application of positive pressure willcause fluid to be expelled out of the pump chamber to the destination.The slave module is optionally equipped with a pressure sensor toperiodically measure or monitor pressure 3284 supplied to the pumpingchamber via the pump control chamber. If 3286 end-of-stroke has not yetbeen detected the slave module controller continues monitoring pressuredata 3284. If 3286 an end-of-stroke is detected from the pressure data,the controller of the slave module performing the pumping stroke reportsthe end-of-stroke condition 3288 on the communications bus. The mastermodule controller or main controller receives the end-of-stroke signaland determines 3290 whether the pumping target (e.g. a target volume tobe transferred) has been reached.

If 3292 the pumping target has not been reached, the master modulecontroller or main controller can either repeat a command signal 3266 tothe slave module to perform another fill stroke, or alternatively in theabsence of a stop or pause command from the master module controller ormain controller, the slave module controller continues itspre-programmed or pre-loaded pumping utility. The operation 3260 mayrepeat from that point until the pumping target has been met. If 3292the pumping target has been reached, the master module controller mayreport 3294 this on the communications bus for receipt by the main orsystem controller. In some aspects, the master module controller mayenter an idle state if 3292 the pumping target has been reached, andreport 3294 the idle state on the communications bus.

Tracking the pumping volume or liquid flow rate can be performed in anumber of ways. For example, the pumping target may be specified by thenumber of pumping strokes. When the number of pumping strokes is equalto the target number, the pumping target may be determined to have beenmet. If the pumping target is specified as pumping volume and is not awhole number multiple of a pump stroke volume, the pumping target may bedeemed to have been met when the first pump stroke that causes thecumulative pumped volume to exceed the pumping target has beendelivered. Alternatively, when the cumulative volume is within a pumpchamber stroke volume of the target volume, the main controller, mastermodule controller, or even the slave module controller may be programmedto determine whether another stroke (and thus an over delivery) wouldyield a cumulative pumped volume that is closer to the target volumethan the current cumulative pumped volume. In some embodiments, if thecumulative pumped volume is within a pump chamber stroke volume of thetarget volume, the volume pumped during the next stroke may be trackedduring the actual stroke and the pump membrane may be halted inmid-stroke when the target volume has been met. Further description oftracking a pumped volume during a stroke is provided in U.S. patentapplication Ser. No. 14/732,571, filed Jun. 5, 2015, entitled MedicalTreatment System and Methods Using a Plurality of Fluid Lines, AttorneyDocket No. Q21 which is incorporated by reference herein in itsentirety.

In an embodiment, the controller of the slave module supplying pressureto the pumping chamber commands pumping actions (with inlet and outletpump valve control) autonomously after receiving a high level commandfrom the main controller. For example, the controller of the slavemodule supplying pressure to the pumping chamber may perform pumpstrokes and determine when the pumping target has been reached. Ifcoordination with another manifold module or group of modules in notneeded, a master module controller may not be needed to coordinatepumping operations. Instead, the slave module may act directly based offof commands from a main controller. Alternatively, if the pumping moduleis paired with a measurement module, the measurement module controllermay determine when the pumping target has been reached.

In some embodiments, a high level pumping command from the maincontroller specifies a pumping source and destination. The master modulecontroller commands modules controlling fluid valves of a pumpingcassette to open or close to place the pump chamber in communicationwith the specified source before a fill stroke is performed. Likewise,the master module controller may command modules controlling fluidvalves of the pumping cassette to open or close to place the pumpchamber in fluid communication with the fluid destination before adelivery stroke is performed.

FIG. 53 depicts a flowchart outlining an example procedure 4700 forcommanding a pump stroke from a pump chamber of a cassette via a numberof valve modules. In the example shown, a first module controls pressureapplied to the pump chamber and a second module controls theinlet/outlet fluid valves of the pump chamber. The procedure 4700 may,however, be readily generalized to embodiments in which the inlet/outletfluid valves of the pump chamber are controlled by more than a singlemodule. In general, the module controlling pressure applied to the pumpchamber may receive a chamber command. This module may then coordinateoperation of paired companion modules so that the proper inlet/outletvalve is opened or closed before the pump stroke begins.

The first module controller may receive 4702 a chamber command. Thechamber command may be a fill or deliver command. This command may begenerated and transmitted as described above in FIGS. 52A-52B. The firstmodule controller transmits 4704 a chamber fluid valve command on thecommunications bus. The second module controller receives 4706 thechamber fluid valve command. The second module controller toggles 4708its chamber fluid valves per the valve states specified in the chamberfluid valve command. The second module controller provides feedback data4710 over the communications bus. This data may include anacknowledgement that the chamber fluid valve command was executed.

The first module controller receives this feedback and command thechamber valves of the first module to apply appropriate pressure(positive for delivery, negative for fill) to the pumping chamber 4712.The first module controller may monitor pressure data 4714 produced by apressure sensor periodically measuring or monitoring the pressuresupplied to the pumping chamber. If 4716 end-of-stroke has not yet beendetected the first module controller continues monitoring pressure data4714.

If 4716 an end-of-stroke is detected from the pressure data, thecontroller of the first module may report the end-of-stroke condition4718 on the communications bus. A master module controller may receiveand act on the end of stroke condition report as described above inrelation FIGS. 52A-52B.

FIG. 54 depicts a flowchart outlining an example procedure 3300 forcommanding coordinated pumping of fluid through multiple pump chambers.Pumping may be coordinated to enhance or maximize throughput of fluid inan efficient manner. For example, pumping can be coordinated to fill onechamber while delivering another, and to minimize or reduce the amountof time a pump chamber is in an idle state.

A main controller can send a pumping command set 3302 specifying whichmodules are to be used to pump the fluid. In this example, the mastermodule controller can be programmed, for example with a primary orgrouped task set (described above in relation to FIG. 47 ), to assign aplurality of modules as constituents of a secondary group. In suchembodiments, the high level command from the main controller may specifya group number or identifier. The master module controller determines3304 which module identities are assigned to the group. The mastermodule controller can then coordinate pumping by addressing chambercommands to those modules assigned to the group identifier. In theexample provided, the master module controller synchronize 3306 pumpingbetween modules assigned to the group by sending commands and receivingfeedback from the modules over the communications bus. If 3308 thepumping target volume has not been reached, the master module controllercontinues synchronizing pumping operations 3306. If 3308 the mastermodule controller determines that the pumping target has been met, themaster module controller may indicate 3310 that the pumping targetvolume has been met over the communications bus to the main controller.

FIG. 55 depicts a flowchart outlining an example procedure 3320 ofcommanding pumping of fluid with one pumping chamber in a filled stateand a pumping command set already having been sent from a maincontroller. The pumping command set is for a group of two pump chambersin this case, although the procedure 3320 may be readily generalized forpumping commands to groups of more than two pump chambers.

The master module controller transmits 3322 a chamber command to eachmodule of the pump group. In this example, the master module controllertransmits 3322 a deliver chamber command to the pre-filled chambermodule and transmits a fill chamber command to the empty chamber module.The master module controller may then monitor the communications bus andwait 3332 for an end-of-stroke indication to be issued from each chambermodule.

The slave modules can monitor the communications bus, the full chambermodule receives the deliver command 3324, and the empty chamber modulereceives the fill chamber command 3326. The full chamber module togglesthe inlet and outlet control valves of the module between positive andnegative pressure lines, and commands the chamber valves to toggle sothat positive pressure is supplied to the pump control chamber 3328. Theinlet and outlet control valves of the full chamber module are toggledso that the pump chamber of the cassette is in communication with adesignated fluid delivery destination. The empty chamber module togglesthe inlet and outlet control valves of the module to connect the pumpchamber with the fluid source, and commands the chamber valves to toggleso that negative pressure is supplied to the pump control chamber 3330.The full chamber module controller may measure or monitor pressure data3334. The empty chamber module controller may measure or monitorpressure data 3336. If 3338 the full chamber module controller does notdetect an end-of-stroke condition or 3340 the empty chamber module doesnot detect an end-of-stroke condition their controllers continue tomonitor pressure data 3334, 3336. If 3338 the full chamber modulecontroller detects an end-of-stroke condition, the full chamber modulecontroller may indicate the condition over the communications bus 3342.If 3340 the empty chamber module controller detects an end-of-strokecondition, the empty chamber module controller may indicate thecondition over the communications bus 3344.

In this example, the master module controller is configured to receivean end-of-stroke indication from both modules 3346. The master modulecontroller determines 3348 if a pumping target has been met, and if so3350, the master module controller transmits an indicator signal 3352 onthe communications bus. If 3350 the pumping target has not been met, theprocedure 3220 repeats from step 3322. Upon each repeated operation, thefull chamber module and empty chamber module will switch modes from fillto deliver and vice versa.

In the example provided, the master module controller waits for bothchamber control module controllers to report an end-of-stroke conditionbefore commanding additional pump strokes. In an additionalconfiguration, the master module controller synchronizes a group ofchamber control modules using one of a set of pre-programmedsynchronization schemes. For example, the master module controller maysynchronize pumping according to any of the pumping synchronizationschemes described in U.S. patent application Ser. No. 14/732,571, filedJun. 5, 2015, entitled Medical Treatment System and Methods Using aPlurality of Fluid Lines, Attorney Docket No. Q21 which is incorporatedby reference herein in its entirety.

FIG. 56 shows an exemplary graph 3500 depicting pressure 3502 of acontrol chamber over time during a pump stroke 3504. In the examplegraph 3500, the pump stroke 3504 is a delivery stroke and positivepressure is supplied to the control chamber. When pressure 3502 issupplied to a control chamber during a pump stroke 3504, the barrier ormembrane between the control and pumping chamber is displaced toward thepumping chamber, delivering fluid and reducing its volume. A volumeincrease in the control chamber will drop its pressure 3502 if notcommunicating with the pneumatic bus at the manifold assembly. A modulecontroller may attempt to keep the pressure 3502 supplied to anassociated control chamber within a range 3506 of a target pressure 3508during the pump stroke 3504. This may require opening and closing amanifold valve separating the control chamber from a pressure source(i.e. pneumatic bus) multiple times over the stroke 3504 when the modulecontroller detects that the pressure 3502 is outside the range 3506.This may help to ensure fluid is pumped at a generally constant flowrate. As shown in the example graph 3500, the pressure 3502 rises andfalls multiple times over the stroke 3504. Each rise in the examplegraph 3500 may correspond with an opening of a valve separating acontrol chamber from a pressure source to repressurize the controlchamber. Each pressure decay may correspond to the control chamberchanging in volume as fluid is pumped by the pumping chamber.

When a pump stroke 3504 has been completed, the control chamber volumeis no longer changing. Consequently, the control chamber pressureremains substantially constant 3510. The module controller may monitorthe pressure of the control chamber to determine if the change inpressure over time is indicative of an end-of-stroke condition. Ingeneral, after a period of time with relatively little pressure change,the module controller may make a determination that an end-of-strokecondition has occurred.

FIG. 57 depicts a flowchart outlining an example procedure 3360 fordetecting an end-of-stroke condition with a chamber control modulecontroller. A module controller issues a valve open command 3362 at thebeginning of a pumping stroke. The module controller monitors pressuredata 3364 generated while the valve is open. If 3366 a minimum wait timehas elapsed and if 3368 the pressure is not greater than or equal to afirst threshold, the module controller continues to monitor pressuredata 3364. If 3366 a minimum wait time has elapsed and if 3368 thepressure is greater than or equal to a first threshold, the modulecontroller issues a valve close command 3370. The module controllercontinues to monitor pressure data 3372 generated while the valve isclosed.

In an exemplary implementation, if 3374 the pressure decay over apredetermined monitoring period is not less than a threshold and if 3382a minimum wait time has elapsed, the procedure 3360 may restart from3362. If 3374 the pressure decay over a predetermined monitoring periodis less than a threshold, the module controller increments a counter3376. If 3378 the counter does not exceed a counter threshold and if3382 a minimum wait time has elapsed the procedure 3360 may be restartedfrom 3362. If 3378 the counter exceeds a counter threshold, the modulecontroller commands valves to an idle state and indicates anend-of-stroke condition over the communications bus 3380. The counterthreshold in an exemplary implementation can be two to three counts. Inthe idle state, the module controller commands the inlet/outlet controlvalves to apply positive pressure to close the inlet and outlet fluidvalves of the pumping chamber. In the idle state, the module controllercommands the chamber control valves to a position in which fluidcommunication between pressure sources and the control chamber has beeninterrupted.

FIG. 58 depicts a flowchart outlining an example procedure 3520 fordetecting an end-of-stroke condition with a chamber control modulecontroller. A module controller issues a valve open command 3522 at thebeginning of a pumping stroke. The module controller monitors pressuredata 3524 generated while the valve is open. If 3526 a minimum wait timehas elapsed and if 3528 the pressure is not greater than or equal to afirst threshold, the module controller continues to monitor pressuredata 3524. If 3526 a minimum wait time has elapsed and if 3528 thepressure is greater than or equal to a first threshold, the modulecontroller issues a valve close command 3530. The module controllercontinues to monitor pressure data 3532 generated while the valve isclosed.

If 3534 a minimum wait time has elapsed and if 3536 the measuredpressure is below the target pressure 3508 (FIG. 56 ), the procedure3520 restarts at 3522. If 3534 a minimum wait time has elapsed and if3536 the measured pressure is below the target pressure 3508 (FIG. 56 ),the module controller checks to if the pressure decay rate over theminimum wait time is less than a threshold. If 3538 the pressure decayrate is greater than the threshold the procedure 3520 restarts at 3522.If 3538 the pressure decay rate is less than the threshold, the modulecontroller commands its valves to an idle state and indicates anend-of-stroke condition over the communications bus 3540.

FIG. 59 depicts a flowchart outlining an example procedure 3550 forlimiting the toggle frequency of a valve within a valve module. A modulecontroller may generate a valve pulse command 3552, causing current tobe passed through the coils of the valve to toggle the valve from afirst position to a second position. The valve pulse command may bepassed 3554 through a filter such as a low pass filter. The voltagevalue after filtering may be monitored 3556. If 3558 the filtered valueexceeds a threshold value for more than a predefined period of time, themodule controller may power off voltage drivers to the valve and willgenerate an error message 3560. If 3558 the filtered value does notexceed the threshold value for more than the predefined period of time,the module controller allows continued operation of the valve 3562. Thetime period may differ depending on the implementation. In one example,the predefined period of time may be 3-7 seconds (e.g. 5 seconds). Thelow pass filter may be tuned so that it limits toggle frequency to adesired value. For example, the toggle frequency may be limited tobetween 20-30 hz (e.g. ˜25 hz or 40 ms). Also, the corner frequency ofthe low pass filter can be adjusted to obtain a filtered valueconsistent with the performance characteristics of the valve assembly.In one example, it can be set to about 0.1 hz.

FIG. 60 depicts a flowchart outlining an example procedure 4400 that maybe used to control the amount of pressure delivered to a pump controlchamber, which in turn can affect the instantaneous flow rate into orout of the pump chamber. in the example, the main controller generates4402 a high level pumping command. This command may be of the typedescribed in relation to FIGS. 52A-52B and may also specify a flow rate.The pump control module controller or the master module controller canreceive 4404 the high level pumping command or command set. The mastermodule controller (if part of the process) determines 4406 a pressurefor a stroke based on the flow rate specified in the high level pumpcommand. In some embodiments, the pressure may be determined 4406 basedon querying a look-up table stored in memory. Alternatively, a pressuremay be computed based on the flow rate specified and a pre-programmedmodel. The master module controller transmits 4408 a chamber command toa slave module controller, which commands execution 4410 of a pumpingstroke. The slave module controller provides feedback 4412 on the stroketo the master module controller after the stroke has been completed. Thefeedback includes a flow rate for the stroke, which is based onmonitored pressure (at a suitable sampling rate) during the pump stroke.The master module controller may use the flow rate data for the strokein a control loop 4414. The control loop can be any suitable type ofcontrol loop such as a PI (proportional-integral) or PID(proportional-integral-derivative) control loop. The control loopoutputs an estimate for the pressure value 4416 for the next stroke ofthat type (e.g. fill stroke, deliver stroke) to be performed. Forexample, the control loop may output a pressure value 4416 for the nextfill stroke if the stroke just completed was a fill stroke. If 4418pumping has not completed (e.g. a pumping target has not been reached),the procedure 4400 may repeat from step 4408 with the new pressure valuefrom the control loop being used when commanding the subsequent strokeof that type.

The various embodiments described herein may be used in any of a varietyof products which use fluid valves. For example, various embodimentsdescribed herein may be used in dialysis machines such as thosedescribed in U.S. Provisional Application Ser. No. 62/008,342, AttorneyDocket No. M24, filed Jun. 5, 2014, and entitled Medical TreatmentSystem Using a Plurality of Fluid Lines, U.S. Provisional ApplicationSer. No. 62/003,374, Attorney Docket No M41, filed May 27, 2014, andentitled Blood Treatment System and Methods, and U.S. ProvisionalApplication Ser. No. 62/003,346, Attorney Docket No. M40, filed May 27,2014, and entitled Hemodialysis System, as well as pneumatic pressurecontrollers such as those described in U.S. Provisional Application Ser.No. 62/029,813, Attorney Docket No. L27, filed Jul. 28, 2014, andentitled Dynamic Support Apparatus.

While the principles of the disclosure have been described herein, it isto be understood by those skilled in the art that this description ismade only by way of example and not as a limitation as to the scope ofthe disclosure. Modifications and substitutions by one of ordinary skillin the art are considered to be within the scope of the presentdisclosure.

What is claimed is:
 1. A manifold pressure measurement module,comprising: a manifold base having a first pressure line inlet port forconnection to a first pressure line containing positively pressurizedgas, a second pressure line inlet port for connection to a secondpressure line containing negatively pressurized gas, a third inlet portfor venting to atmospheric pressure, and a fourth inlet port forconnection to a control chamber of a pneumatically actuated diaphragmpump; first, second third and fourth valve assemblies, each mounted to avalve assembly receiving station on the manifold base; a controllermounted to the manifold base and connected to the four valve assemblies;the manifold base configured to fluidically connect the first pressureline inlet port to a first inlet of the first valve assembly, tofluidically connect the second pressure line inlet port to a first inletof the second valve assembly, to fluidically connect the third inletport to a first inlet of the third valve assembly, and to fluidicallyconnect the fourth inlet port to a first inlet of the fourth valveassembly; the manifold base also configured to connect valve cavities ofeach valve assembly to respective pressure sensing ports of the manifoldbase, and to connect each of the valve cavities to a reference reservoirof known volume; the first, second, third and fourth valve assembliesconfigured to be selectively electrically actuated by the controller toopen or close communication between the valve cavities of each of saidvalve assemblies and the first inlets of each of said valve assemblies;the controller comprising first, second, third and fourth pressuresensors mounted on a control board, the pressure sensors configured toform a reversible sealed connection respectively with the pressuresensing ports of the manifold base; wherein the controller is configuredto operate the first, second, third and fourth valve assemblies tocharge the reference reservoir with positive or negative pneumaticpressure, or to open the reference reservoir to atmospheric pressure,and to fluidically connect the reference reservoir with the controlchamber of the diaphragm pump to equalize pressures between the controlchamber and the reference reservoir, and to record pressures at one ormore of the pressure sensing ports before and after pressureequalization.
 2. The manifold pressure measurement module of claim 1,wherein the controller receives and processes pressure data generated byeach of said pressure sensors to determine a volume pumped or displacedover a pumping stroke of said diaphragm pump.
 3. The manifold pressuremeasurement module of claim 2, wherein one of said valves is operated toisolate the control chamber from the reference chamber before saidpumping stroke and the reference chamber is pressurized to a desiredpressure.
 4. The manifold pressure measurement module of claim 3,wherein a first pressure in the isolated control chamber and referencechamber are measured with respective pressure sensors and recorded bythe controller, the reference chamber and isolated control chamber arethen placed in fluid communication with one another and their pressuresare allowed to equalize, the equalized pressure is then measured withrespective pressure sensors and compared to said first pressures andcompared to determine a volume of the control chamber
 5. The manifoldpressure measurement module of claim 4, wherein said pressure comparisonis completed before and after said pumping stroke, the controllerrecording and comparing a pre-stroke volume and a post-stroke volume ofthe control chamber to determine a volume change which is recorded asthe amount of liquid pumped during the stroke.
 6. A manifold pressuremeasurement module of claim 1, further comprising: a pump connected toand controlled by said pressure measurement module, wherein a liquidinlet valve of said pump is in fluid communication with one of saidvalve assemblies, said valve assembly opening and closing said liquidinlet valve and an outlet valve of said pump is in fluid communicationwith a second one of said valve assemblies, said valve assembly openingand closing said outlet valve.
 7. The manifold pressure measurementmodule of claim 6, further comprising: a third one of said valveassembles in fluid communication with the pump control chamber toperform a pump deliver stroke, and a fourth one of said valve assembliesin fluid communication with the pump control chamber to perform a pumpfill stroke.
 8. A valve assembly comprising: a valve cavity having atleast a first inlet and at least a first outlet; a shuttle within saidvalve cavity configured to move linearly from a first position blockingsaid at least first inlet to a second position allowing the at leastfirst inlet to fluidly communicate with the valve cavity; and a moldedinsert having an outer wall configured to conform to an inner wall ofthe valve cavity, and having an inner wall configured to surround theshuttle and permit the shuttle to move from the first position to thesecond position.
 9. The valve assembly of claim 8, wherein of theshuttle is actuated electromagnetically, magnetically, or through abiasing force applied by a spring
 10. The valve assembly of claim 8,wherein the molded insert is manufactured from an elastomeric or plasticmaterial that reduces acoustical noise generated by movement of theshuttle.
 11. The valve assembly of claim 8, further comprising: themolded insert having an inlet orifice configured to mate with the firstinlet of the valve cavity and to be interposed between the first inletof the valve cavity and a first face of the shuttle.
 12. The valveassembly of claim 8, further comprising: the molded insert having anoutlet orifice configured to fluidly communicate with a fluid outlet ofthe valve cavity.
 13. A fluid pumping system comprising: a cassettehaving a flexible diaphragm; a system controller; and a manifold modulecomprising: a manifold base having a pressure line inlet port, an outletport to a pressure line containing pressurized fluid and a pressuresensing port; a first valve assembly having a valve cavity and an inletand an outlet, said valve assembly mounted to the manifold base; and amodule controller mounted to the manifold base and connected to thevalve assembly; the manifold base configured to fluidically connect saidpressure line inlet port of the manifold base to said inlet of the valveassembly, to fluidically connect said valve cavity to said pressuresensing port of the manifold base, to fluidically connect an outlet ofthe valve assembly to an outlet port of the manifold base, and tofluidically connect the pressure line inlet port to the pressure lineoutlet port of the manifold base, wherein the first valve assembly iselectrically actuated by the module controller to either open or blockcommunication between the inlet of the valve assembly and the cavity ofthe valve assembly, and the cavity of the valve assembly being in fluidcommunication with the outlet of the valve assembly.
 14. The fluidpumping system of claim 13, wherein the module controller includes apressure sensor mounted on a control board, the pressure sensorconfigured to form a reversible sealed connection with the pressuresensing port of the manifold base, the control board having one or moreelectrical output connectors for connection to an electromagnetic coilto actuate the valve assembly.
 15. The fluid pumping system of claim 14,wherein the control board, having a first electronic communicationsconnector for sending and receiving electronic communications to or froma communications bus on a first side of the manifold module, and havinga second electronic communications connector for sending and receivingelectronic communications to or from the communications bus on a secondside of the manifold module, the control board configured to receive asummary command from the system controller, the control board configuredto generate, based on the summary command, at least one module commandaddressed to the first valve assembly, the at least one module commandenabling selective application of pressure to the flexible diaphragm,16. The fluid pumping system of claim 15, wherein the manifold module isconfigured to reversibly connect with a second manifold module via thefirst or second electronic communications connector and via the pressureline inlet port or the pressure line outlet port of the manifold base.